Suzuki Samurai 1987 Manuals

Manuals and User Guides for Suzuki Samurai 1987. We have 1 Suzuki Samurai 1987 manual available for free PDF download: Service Manual

Suzuki Samurai 1987 Service Manual

Suzuki Samurai 1987 Service Manual (483 pages)

Brand: Suzuki | Category: Automobile | Size: 279.34 MB

Table of Contents

Table of Contents
3
General, Special Tools and Service Materials
4
Identification Number
4
Vehicle Identification Number
4
Engine Identification Number
4
Standard Shop Practices
5
Front Side
5
Rear Side
5
Rear Support Location
6
Front Support Location
6
When Using Frame Contact Hoist
6
Engine Cylinder Numbers
7
Special Tools
8
Required Service Materials
9
Metric Information
16
Metric Fasteners
16
Fastener Strength Identification
16
Standard Tightening Torque
17
Periodic Maintenance Service
18
Maintenance Recommended under Severe Driving Conditions
21
Severe Condition Code
21
Engine and Emission Control
22
Water Pump Belt Inspection and Replacement
22
Camshaft Timing Belt Inspection
22
Valve Lash Inspection
23
Cooling System Hoses and Connections Inspection
24
Proper Engine Oil Viscosity Chart
24
Engine Oil Capacity
24
Engine Coolant Change
24
Engine Oil and Filter Change
25
Exhaust Pipes and Mountings Inspection
26
Coolant Capacity
26
Bolts and Nut
26
Pcv Valve Replacement
27
Oxygen Sensor Replacement
27
Catalytic Converter Inspection
27
Charcoal Canister Replacement
28
Emission-Related Hoses and Tubes Inspection
28
Ecm and Associated Sensors Inspection
29
Wiring Harness and Connections Inspection
29
Spark Plugs Replacement
29
Plug Specification
30
Ignition Wiring Replacement
30
Distributor Cap and Rotor Inspection
30
Distributor Advancer Inspection
30
Fuel Filter Replacement
31
Carburetor Choke System Lubrication and Inspection
31
Air Cleaner Element
31
Fuel Tank Cap Gasket Inspection
31
Idle Speed Inspection
32
Idle Mixture Inspection
32
Mixture Adjusting Screw Pin
33
Carburetor Inspection
33
Chassis and Body
34
Clutch Pedal Inspection
34
Brake Discs, Pads, Brake Drums and Shoes Inspection
34
Brake Pedal Inspection
34
Free Wheeling Hub
35
Wheel Bearing Inspection
35
Tire Inspection and Rotation
35
Parking Brake Cable
35
Shock Absorbers Inspection
36
Propeller Shafts Inspection and Lubrication
36
Transfer Oil Change
37
Differential Oil Change (Front and Rear)
37
Transmission Oil Change
37
Steering System Inspection
38
Door Hinges Lubrication
38
Bolts and Nuts Tightening
38
Alignment Service Data
38
Final Inspection
39
Table of Contents
40
Trouble Shooting
40
Engine
41
Carburetor
48
Exhaust and Muffler
48
Clutch
48
Transmission
49
Differentials
50
Propeller Shafts
51
Brakes
51
Suspension, Steering System and Tires
53
Starting Motor
55
Alternator
56
Wiper Motor
57
Fuel Meter
57
Speedometer
58
Water Temperature Meter
58
- Engine
  59
- General Description
  60
- Engine Services Not Requiring Engine Removal
  63
- Engine Removal
  64
- Engine Disassembly
  67
- Inspection of Engine Components
  75
  - Flatness of Gasketed Surface
    76
  - Rocker-Arm Shaft and Rocker Arms
    77
  - Runout of Rocker-Arm Shaft
    77
  - Valve Guides
    77
  - Valves
    78
  - Seating Contact Width
    79
  - Valve Seats
    79
  - Exhaust Valve Seat
    80
  - Valve Lapping
    80
  - Valve Seat Repair
    80
  - Measuring Free Length of Spring
    81
  - Measuring Spring Preload
    81
  - Spring Squareness
    81
  - Valve Springs
    81
  - Cam Wear
    82
  - Camshaft
    82
  - Journal Wear
    82
  - Runout of Camshaft
    82
  - Cylinder Bore
    83
  - Distortion of Gasketed Surface
    83
  - Positions to be Measured
    83
  - Honing or Reboring Cylinders
    84
  - Piston and Piston Rings
    84
  - Measuring Piston Ring End Gap
    85
  - Piston Pins
    85
  - Piston Ring End Gap
    85
  - Ring Groove Clearance
    85
  - Connecting Rod Alignment
    86
  - Crank Pin and Connecting Rod Bearings
    86
  - Rod Bearing Clearance
    86
  - Crankshaft Thrust Play
    87
  - Measuring Rod Bearing Clearance
    87
  - Crankshaft Main (Journal) Bearings
    88
  - Out-Of-Round and Taper (Uneven Wear)
    88
  - Upper Half of Bearing Installation
    88
  - Paint on Standard Bearing
    90
  - Faints on Undersize Bearing
    91
  - Flywheel
    92
  - Oil Pump
    92
  - Radial Clearance
    92
  - Rear Oil Seal
    92
- Engine Reassembly
  93
  - Radial Clearances
    93
  - Timing Belt End Tensioner
    93
  - Crankshaft
    94
  - Ins Tatting Thrust Bearing
    94
  - Installing Bearing Half with Oil Groove
    94
  - Cutting off Edges of Gasket
    95
  - Oil Seal Housing
    95
  - Piston, Connecting Rod and Piston Rings
    96
  - Fitting Connecting Rod to Piston
    97
  - Fitting Piston to Special Tool
    97
  - 14 Instatting Piston Pin
    98
  - Line Marked on Driver Handle
    98
  - Piston Ring End Gaps Positions
    98
  - Guide Hoses Installation
    99
  - Instailing Bearing Cap
    99
  - Installing Piston to Cylinder
    99
  - Applying Sealant to Oil Pan
    100
  - Oil Level Gauge Guide
    100
  - Oil Pan
    100
  - Oil Pump Strainer
    100
  - Cylinder Head
    101
  - Reaming Guide Hole
    101
  - Reaming Valve Guide Bore
    101
  - Valve Guide Installation
    101
  - Valve Installation
    102
  - Valve Spring Installation
    102
  - Valve Stem Seal Installation
    102
  - Camshaft Installation
    103
  - Valve Totters Installation
    103
  - Intake Manifold and Carburetor
    104
  - Rocker Arm Shafts Installation
    104
  - Rocker-Arm Shafts
    104
  - Water Inlet Pipe
    104
  - Exhaust Manifold and Cover
    105
  - Oil Filter
    105
  - Water Pump
    105
  - Installing Guide, Key and Pulley
    106
  - Pulley Pin, Slot and Pulley Bolt
    106
  - Timing Belt Inside Cover, Belt Pulleys
    106
  - Lug and Hole
    107
  - Timing Marks
    107
  - Valve Adjusting Screw and Lock Nut
    107
  - Installing Timing Belt
    108
  - Tensioner Bolt and Nut
    108
  - Distributor Case
    109
  - Fuel Pump
    109
  - Fuel Pump Rod Installation
    109
  - Installing Crankshaft Pulley
    109
  - Clutch Disc and Cover
    110
  - Cylinder Head Cover
    110
  - Transmission Assembly
    110
  - Valve Lash (Clearance) Adjustment
    110
  - Checking and Adjusting Procedures
    111
- Engine Installation
  111
- Engine Maintenance Service
  111
  - Ignition Timing
    111
  - Camshaft Timing Belt
    112
  - Engine Oil Filter
    112
  - Measuring Valve Lashes
    112
  - Compression Pressure Measurement
    113
  - Engine Coolant
    113
  - Exhaust Line and Muffler
    113
  - Oil Pump Discharge Pressure Measurement
    113
  - Oil Pressure Gauge Installation
    114
  - Oil Pressure Switch
    114
  - Vacuum Measurement
    114
  - Oil Filler Cap
    115
- Recommended Torque Specifications
  116
- Fuel System
  117
- Carburetor
  118
- General Description
  118
  - Float System
    121
  - Mixture Control Solenoid Valve
    122
  - Primary Slow System
    122
  - Primary System
    122
  - Switch Vent Solenoid
    122
  - Fuel Cut System
    123
  - Secondary Slow System
    124
  - Secondary System
    124
  - Acceleration Pump System
    125
  - Secondary Main System
    125
  - Choke System
    126
  - Operation of Choke System
    126
  - When Coolant Temperature Is Low
    126
  - When the Coolant Temperature Rises
    126
  - Idle up System
    127
  - Idle-Up System Operation
    127
  - Unloader System
    127
  - When Coolant Temp. Rises
    127
- Removal and Installation
  128
- Unit Repair Overhaul
  129
  - Air Horn and Hoses, Etc
    130
  - Needle Valve Seat and Filter
    130
  - Drain Plugs
    131
  - Throttle Chamber
    131
  - Hooking Throttle Lever Return Spring
    132
  - Installing Washer
    132
  - Primary and Secondary Main Jets
    132
  - Installing Drain Plugs
    133
  - Installing Jets and Air Bleeders
    133
  - Accelerator Cable Adjustment
    135
- Maintenance Services
  135
  - Float Adjustment
    136
  - Fuel Level
    136
  - Idle up Adjustment
    136
  - Idle-Up Adjusting Screw
    136
  - Checking Actuator
    137
  - Checking TWSV
    137
  - Checking TWSV Circuit
    137
  - Choke Adjustment
    138
  - Choke Valve
    138
  - Checking Choke Piston
    139
  - Choke Lever
    139
  - Choke Piston
    139
  - Fast Idle Adjustment
    140
  - Mark on Cam and Cam Follower
    140
  - Unloader Adjustment
    140
  - Checking Acceleration Pump
    141
  - Checking Secondary System
    141
  - VTV (Vacuum Transmitting Valve)
    141
  - Idle Speed Adjustment
    142
  - Idle Mixture Adjustment
    143
  - Idle Mixture Inspection and Adjustment
    143
- Air Cleaner
  145
- General Description
  145
- Maintenance Services
  145
- Fuel Pump, Filter and Lines
  147
- General Description
  147
  - Fuel Filter
    148
  - Fuel Pulp
    148
  - Fuel Filler Cap
    149
  - Fuel Filler Cap Cross-Section
    149
- Removal and Installation
  149
  - Fuel Tank
    150
  - Fuel Filler (Tank) Cap
    151
  - Fuel Lines
    151
  - Fuel Tank Purging Procedure
    151
- Maintenance Services
  151
- Accelerator Pedal
  152
- Positive Crankcase Ventilation (Pcv) System
  157
  - TCAC System Operation
    158
  - Thermostatically Controlled Air Cleaner (Tcac) System
    158
- (Tcac) System
  159
- Evaporative Emission Control System
  159
- Hot Idle Compensator (Hic)
  160
- Deceleration Mixture Control System
  161
- Computer Controlled Emission Control System
  162
  - Electronic Control Module
    162
  - Feed Back System
    162
  - Engine Coolant Temperature
    163
  - Engine Speed
    163
  - Throttle Position
    163
  - Altitude Compensation
    164
- Bowl Ventilation System
  164
  - Gear Position
    164
  - Three-Way Catalyst
    164
- Fuel Cut System
  165
- Exhaust Gas Recirculation (Egr) System
  166
- Diagnosis
  167
  - Possible Causes of Emissions Test Failures
    167
  - Pcv System Diagnosis
    169
  - Checking PCV System
    170
  - Checking PCV Valve for Sticking
    170
- General
  170
- Maintenance Service
  170
  - PCV Hoses
    170
  - Air Control Actuator
    171
  - Checking TCAC System
    171
- Tcac System
  171
  - Thermo Sensor
    171
  - Checking Canister
    172
  - Checking Check Valve
    172
  - Checking Vapor Storage Canister
    172
- Evaporative Emission Control System
  172
- Deceleration Mixture Control System
  173
- Hot Idle Compensator (Hic)
  173
- Mixture Control Valve (MCV)
  173
- Feed Back System
  174
  - System Check Flow Chart
    174
  - Checking Feed Back System
    175
  - Checking Idle and Wide Open Micro Switches
    175
  - Idle Micro Switch
    176
  - Checking Mixture Control Solenoid Valve
    177
  - Checking Wide Open Micro Switch
    177
  - Wide Open Micro Switch
    177
  - Wide Open Micro Switch Lever
    177
  - Checking Thermal Switch
    178
  - Checking High Altitude Compensator
    179
  - Checking Switch in Hot Water
    179
  - Checking Thermal Engine Room Switch
    179
  - Checking Oxygen Sensor
    180
  - Connector of Oxygen Sensor
    180
  - Disconnecting Vacuum Hose
    180
  - Moving Lever
    180
  - Checking ECM Ground Circuit
    181
  - Checking ECM Ground Circuits
    181
  - Checking Feed Back System Circuits
    181
  - ECM and Coupler
    181
  - Body Ground
    182
  - Engine Ground
    182
  - Checking ECM Power Circuits
    183
  - Checking Sensors and Their Lead Wires
    184
  - Checking Function of Oxygen Sensor and Feed Back System
    185
  - Checking Idle-Up Signal
    187
  - Checking Fuel Cut System
    188
  - Checking Switch Vent Solenoid
    188
  - Replacing ECMI
    188
  - Checking EGR System
    189
  - Checking EGR Valve Diaphragm
    189
  - Movement of EGR Valve Diaphragm
    189
  - Vacuum Hoses
    189
  - Bi-Metal Vacuum Switching Valve (BVSV)
    190
  - Checking EGR Modulator
    190
  - Filter of EGR Modulator
    190
  - Engine Cooling System
    192
- 6-L. GENERAL DESCRIPTION
  193
  - Cooling System Circulation
    193
  - Radiator Cap
    194
  - Water Reservoir Tank
    194
- Thermostat
  195
  - Coolant Draining
    196
  - Cooling Water Pipes or Hoses
    196
- Radiator
  196
  - Water Pump Drive Belt
    196
  - Inspection of Components
    198
- Water Pump
  199
- Important Steps for Reinstallation
  200
- Thermostat
  200
- Water Pump
  200
- Maintenance Service
  201
- Radiator
  201
- Water Pump Belt
  201
- Anti-Freeze Proportioning Chart
  202
- Coolant Level
  202
- Cooling System Service
  203
- Cooling System, Flush and Refill
  203
  - Installation of Radiator Cap
    203
  - Radiator Drain Plug
    203
  - Cooling Fan Clutch
    204
  - Car Heater
    205
  - Electrical Circuit
    207
  - Blower Resistor
    208
  - Blower Switch
    208
  - Heater Hoses
    208
  - Heater Services
    208
  - Heater & Ventilator Control Cable Routing
    211
  - Ignition System
    212
- Distributor
  213
- General Description
  213
- Ignition Coil
  215
- Spark Plug
  215
- Distributor
  216
- High Tension Cord
  216
- Ignition Coil
  216
- Maintenance Service
  216
- Spark Plug
  216
  - Signal Rotor Air Gap
    217
  - Distributor Driven Gear
    219
- Ignition Timing
  220
- Checking Vacuum Advancer
  221
- Distributor Drive Gear
  221
- Distributor
  222
- High Tension Cords Distribution
  222
- Important Reminders for Installation
  222
  - Cranking System
    223
  - Cranking Circuit
    224
- General Description
  224
- Starting Motor
  224
- Specifications
  226
- Lubrication
  227
- Removal and Installation
  227
- Disassembly
  228
- Inspect Commutator
  229
- Starting Motor Inspection
  229
  - Ground Test
    230
  - Inspect Brush
    230
  - Inspect Field Coil
    230
  - Open Circuit Test
    230
  - Inspect Armature Shaft Bush
    231
  - Inspect Brush Holder and Spring
    231
  - Inspect Drive Lever
    231
  - Hold in Coil Open Circuit Test
    232
  - Inspect Magnetic Switch
    232
  - Pull-In Coil Open Circuit Test
    232
- Hold-In Test
  233
  - No-Load Performance Test
    233
  - Performance Test
    233
- Pull-In Test
  233
- Clutch Switch
  234
- Charging System
  235
- 10-L. ALTERNATOR
  236
- General Description
  236
- Data and Specification
  237
- Diagnosis
  237
  - Noisy Alternator
    237
  - Faulty Indicator Lamp Operation
    238
  - Undercharged Battery
    238
  - Voltmeter
    238
  - Load Check
    239
  - Overcharged Battery
    239
  - Alternator Service
    240
- Removal
  240
- Inspection
  242
  - Rotor
    242
  - Stator
    242
- Assembly
  243
  - Brush and Brush Holder
    243
  - Condenser
    243
  - Rectifier
    243
- Care of the Battery
  244
- General Description
  244
  - Built-In Indicator
    245
  - Carrier and Hold-Down
    245
  - Visual Inspection
    245
  - Battery Cables
    246
- Remove and Replace
  246
- Clutch
  247
- 11-L. GENERAL DESCRIPTION
  248
  - Clutch Cover and Disc
    250
  - Clutch Release Bearing
    250
  - Clutch Release Shaft Bushes
    250
  - Input Shaft End Bearing
    250
- Removal
  250
  - Backlash in Disc Setration Fit
    251
  - Clutch Cover
    251
  - Clutch Disc Facing Surface Condition
    251
  - Clutch Facing Wear
    251
- Inspection of Components
  251
  - Input Shaft Bearing
    252
  - Release Bearing
    252
  - Clutch Disc and Clutch Cover
    253
- Installation
  253
  - Clutch Pedal Height
    254
  - Clutch Release Arm
    254
  - Clutch Release Shaft Fork
    254
  - Maintenance Services
    254
  - Clutch Cable Lubrication
    255
  - Clutch Cable Routing
    255
- Recommended Torque Specification
  256
- Gear Shifting Control
  257
- General Description
  258
- Gear Shift Lever Select Guide Pins
  259
- Removal
  259
- Gear Shift Fork Shaft
  260
- Gear Shift Lever
  260
- Inspection of Components
  260
- Reverse & Low Speed Select Guide Pins
  260
- Gear Shift Lever Case
  261
- Installation
  261
- Reverse & Low Speed Guide Pins
  261
- Gear Shift Control Lever Seat
  262
  - Transmission
    263
  - In Engine Room
    266
  - In Passenger Compartment
    266
  - Under Engine
    266
  - Precautions on Bush Reinstallation
    267
  - Replacing Clutch Release Shaft Bush
    267
  - Separating Upper Case from Lower Case
    268
  - Removing Countershaft
    269
  - Removing Main Shaft and Input Shaft
    270
  - Gear Shift Fork and Shaft
    272
  - Gear Shift Yoke
    272
  - Neutral Position
    272
  - Removing Shift Yokes, Forks and Shafts
    272
  - Bearings and Bushes
    274
  - Gears
    274
  - Main Shaft
    274
  - Synchronizer Hubs, Sleeves and Keys
    274
  - Chamfered Tooth Ends of Ring
    275
  - Combination of Gear and Synchronizer Ring
    275
  - Input Shaft
    275
  - Fork Shaft Locating Springs
    276
  - Synchronizer Rings
    276
  - Extension Case Bush
    277
  - Gear Shift Shafts
    277
  - Main Shaft and Input Shaft
    277
  - Gear Shift Fork
    282
  - Yokes
    283
  - Transmission Lower Case and Upper Case
    284
  - Extension Case
    285
  - Input Shaft Bearing Retainer
    286
  - Transmission Oil
    287
  - Transfer Gear Box
    289
- General Description
  290
  - 2-Wheel Drive (Rear-Wheel Drive)
    291
  - 4-Wheel Drive HIGH (All-Wheel Drive on HIGH)
    291
- Selective Flows of Transfer Drive
  291
- 4-Wheel Drive LOW (All-Wheel Drive on LOW)
  292
- Gear Ratio Data
  292
- Transfer Services Not Requiring Transfer Removal
  293
- Removal
  294
- Disassembly
  296
  - Speedometer Driven Gear
    296
  - Transfer Front Case
    296
  - Universal-Joint Yoke Flanges
    296
  - Transfer Center Case
    297
  - Gear Teeth
    300
- Inspection of Components
  300
  - Locating Spring
    300
  - Transfer Rear Case
    300
  - Output High Gear
    301
  - Output Low Gear
    301
  - Side Clearance of Gears
    301
  - 4WD Gear Shift Lever
    302
- Reassembly
  302
  - Output Rear Shaft
    303
  - Shim Adjustment of Input and Output Shafts
    304
  - Center Case
    306
  - Center and Rear Cases
    308
  - Front Case
    309
- Maintenance Services
  310
  - Oil and Oil Capacity
    310
  - Oil Level
    310
- Tightening Torque
  311
- Propeller Shafts
  312
- General Description
  313
- Installation
  314
- Removal
  314
- Maintenance Services
  315
  - Universal Joint Noise
    315
  - Bolts & Nuts
    316
- Tightening Torque
  316
- Disassembling on Flange Yoke Side
  317
- Reassembly
  318
- Differential
  320
- General Description
  321
- Removal
  322
- Disassembly
  325
- Inspection and Adjustment of Components
  326
- Reassembly
  332
  - Bevel Pinion Bearings
    333
  - Brake Circuit Air Purging
    334
  - Differential Gear Oil
    334
- Installation
  334
  - Rear Brake Drum
    334
  - Side Bearings Caps
    334
- Maintenance Services
  335
- Oil Change
  335
- Recommended Torque Specifications
  335
  - Suspension
    336
  - Front Suspension
    337
  - Barfield Joint Construction and Operation
    339
  - Leaf Spring
    340
  - Shock Absorber
    340
  - Stabilizer
    340
  - Front Wheel Hub 81 Bearing
    341
  - Circlip Remover
    342
  - Steering Knuckle
    343
  - Front Axle Shaft Joint
    344
  - Barfield Joint
    345
  - Front Wheel Bearing
    345
  - Leaf Spring Bushes
    345
  - Stabilizer and Its Bush
    345
  - Kingpins and Bearings
    346
  - Steering Knuckle Oil Seal
    346
  - Rear Suspension
    350
  - Rear Axle Shaft
    351
  - Leaf Spring and Bumper
    355
  - Bolts and Nuts
    359
  - Rear Wheel Bearing
    359
  - Front Free Wheeling Hub
    362
  - Steering System
    365
- General Description
  366
  - Right-Hand Steering Vehicle
    366
  - Left-Hand Steering Vehicle
    367
- Specifications and Data
  368
- Removal
  369
  - Steering Column
    369
  - Steering Hand Wheel
    369
  - Gear Box
    372
  - Steering Lock
    372
  - Tie Rod and Tie Rod End
    372
  - Adjustment of Worm Shaft Starting Torque
    373
- Inspection of Components
  373
  - Left Hand Steering Vehicle
    373
  - Steering Gear Box
    373
- Checking Steering Column for Accident Damage
  375
- Important Steps in Reinstallation
  376
  - Steering Damper
    377
  - Steering Handwheel
    380
  - Toe Setting
    380
- Wheel Alignment
  380
  - Camber
    381
  - Camber and Caster Adjustment
    381
  - Reference Information
    381
  - Toe Adjustment
    381
- Maintenance Services
  382
  - Steering Handwheel Play
    382
  - Steering Rubber Joint
    382
  - Steering Shaft Joint
    382
  - Tire Wear Indicato
    383
  - Tires
    383
  - Inflation of Tires
    384
  - Tire Rotation
    384
  - Wheels
    384
  - Tire Demounting and Mounting
    385
  - Tire Repair
    385
- Recommended Torque Specifications
  386
- Brakes
  387
- General Description
  388
  - Master Cylinder Assembly
    390
  - Master Cylinder OPERATION
    390
  - Normal Operation
    390
  - One-Circuit Operation
    391
  - Disc Brake Caliper Assembly
    392
  - Clearance Correction
    393
  - Single Piston Floating Caliper Type
    393
  - Drum Brake Assembly
    394
  - Rear Brake Operation
    395
  - Booster Assembly
    397
  - Booster
    398
  - Vacuum Booster Assembly
    398
  - When Foot Brake Pedal Is Not Depressed
    398
  - When Foot Brake Pedal Is Depressed
    399
  - When Foot Brake Pedal Is Released
    399
  - Brake Pad
    400
- Front Disc Brake
  400
  - Caliper
    401
  - Disc
    402
  - Brake Disc
    403
  - Bush Dust Boot and Cylinder Boot
    403
  - Cylinder Slide Bush
    403
  - Piston and Boot
    404
  - Piston Seal
    404
  - Precautions on Installation
    404
  - Front Brake Disc and Pad
    405
  - Front Brake Flexible Hose
    405
  - Front Wheel Spindle
    405
  - Brake Drums
    406
  - Inspection for Front Brake after Installing
    406
- Rear Drum Brake
  406
  - Brake Drum
    407
  - Brake Shoes and Strut
    407
  - Cracked, Scored, or Grooved Drum
    407
  - Brake Shoe and Rim
    408
  - Brake Strut
    408
  - Wheel Cylinder
    408
  - Self Shoe Clearance Adjusting System
    409
  - Springs
    409
  - Master Cylinder
    413
  - Master Cylinder Inner Parts
    414
  - Reservoir
    414
  - Precaution of Installation
    415
- Brake Booster
  416
  - Inner Parts
    419
  - Metal Parts
    419
  - Rubber Parts
    419
  - Booster Inspection Table
    420
- Parking Brake
  424
- Brake Pipes and Hoses
  425
  - B-Way Joint
    426
  - Brake Flexible Hose and E-Ring
    426
  - Clamp
    426
  - Upper Side
    426
  - Brake Pipes (Right
    427
  - Brake Fluid Leaks
    428
  - Brake Fluid Level Inspection
    428
  - Fill Reservoir
    428
- Maintenance Service
  428
  - Road Testing Brakes
    428
  - Brake Pedal Free Height Adjustment
    429
  - Excessive Pedal Travel Check
    429
  - Stop Light Switch Adjustment
    429
  - Brake Hose and Pipe Inspection
    430
  - Disc Inspection
    430
  - Hose
    430
  - Rear Brake Shoe & Lining Inspection
    430
  - Brake Pedal Play Inspection
    431
  - Flushing Brake Hydraulic System
    431
  - Parking Brake Lever Stroke Adjustment
    431
  - Rear Drum Brake Shoe Adjustment
    431
  - Bleeding Brakes
    432
  - Check Air Tightness
    433
  - Inspect Booster Operation
    433
  - Inspection Without Tester
    433
  - Check Air Tightness under Load
    434
  - Check Operation
    434
- Torque Specification
  435
- Body Service
  436
- Description
  437
- Front Door
  437
  - Door Window Glass
    438
  - Door Glass
    440
  - Door Window Glass or Regulator
    440
  - Door Window Regulator
    440
  - Front Door Lock
    440
- Installation
  440
  - Door Outside Open Rod
    441
  - Regulator Handle
    441
  - Water Proof Film
    441
  - Door Lock Inside Handle
    442
  - Door Lock Rod Pin
    442
  - Door Lock Striker
    442
  - Cleaning
    443
  - Windshield
    443
- Installation
  444
- Back Door (Applicable to Hard Top Vehicle)
  446
  - Door Lock and Stricker Adjustment
    446
  - Door Lock Stricker
    447
  - Handling of Back Door Balancer
    447
  - Chassis Dimensions
    448
  - Body Electrical Equipment
    449
  - Combination Meter
    450
  - Combination Meter Circuit and Components
    450
  - Combination Meter with Tachometer
    451
  - Combination Meter Without Tachometer
    451
- Head Light
  452
  - Wiring Circuit
    452
  - Beam Alignment
    453
  - Headlight Beam Setting (Standard Procedure)
    453
  - Headlight Inspection
    453
  - Combination Switch (Lighting Switch Circuit)
    454
  - Head Light Dimmer Switch
    454
  - Headlight Adjustment
    454
  - Switch Connector
    454
- Turn Signal Light and Hazard Warning Light
  455
  - Hazard Warning Switc
    456
  - Turn Signal & Hazard Warning Switch
    456
  - Turn Signal Switch
    456
  - 2-Speed Type
    457
  - Interval Wiper Relay Circuit
    457
- Windshield Wiper Motor
  457
  - No-Load Run Test
    458
  - Wiper Trouble Diagnosis
    458
  - Automatic Stop Action Test
    459
  - Internal Wiper Relay Test
    459
- Water Temperature Meter and Gauge
  459
- Fuel Level Meter and Gauge
  460
  - Gauge Unit
    460
  - Resistance- Temp. Relationship
    460
- Brake Warning Lamp
  461
  - Resistance-Fuel Level Relationship
    461
  - Brake Fluid Level Switch
    462
- Oil Pressure Lamp
  462
- 4WD Switch
  463
- Seat Belt Warning Lamp/Buzzer
  463
- Wheel Drive Lamp
  463
- Ilumination Controller
  464
- Main Switch Key Warning Buzzer
  464
- REAR DEFOGGER ( Hard-Top )
  464
  - Checking Wire for Damaged Place
    465
  - Defogger Circuit
    465
  - Defogger Wire
    465
  - Repair
    465
- Fuse Box
  466
- Engine Room Wiring
  467
- Wiring Harness Routing
  467
- Instrument Panel Wiring
  469
- Wiring Diagram
  470
Service Data
471

Related Products

Suzuki Categories

Motorcycle Automobile Motorcycle Accessories Offroad Vehicle Musical Instrument

More Suzuki Manuals