MARUTI SUZUKI 800 Manuals

Manuals and User Guides for MARUTI SUZUKI 800. We have 2 MARUTI SUZUKI 800 manuals available for free PDF download: Service Manual, Owner's Manual

MARUTI SUZUKI 800 Service Manual (644 pages)

Brand: MARUTI SUZUKI | Category: Automobile | Size: 10 MB

Section 0A General Information

4
Maintenance and Lubrication

20
- Periodic Maintenance Schedule
  
  21
- Maintenance Service
  
  24
  - Engine
    24
  - Ignition System
    29
  - Fuel System
    30
  - Emission Control System
    31
  - Brake
    32
  - Chassis and Body
    33
  - Final Inspection
    38
- Recommended Fluids and Lubricants
  
  39
Section 1A Heater (Optional) and Ventilation

40
- General Description
  
  41
- Heater (Optional) and Ventilation
  
  41
- Diagnosis
  
  42
  - Diagnosis Table
    42
  - Wiring Circuit
    43
- On Vehicle Service
  
  44
  - Heater Unit
    44
  - Blower Fan Motor
    46
  - Blower Fan Motor Resistor
    47
  - Heater Control Lever Assembly
    48
  - Blower Fan Motor Switch
    50
  - Air Inlet Box
    51
Section 1B Air Conditioning (Optional)

52
- General Description
  
  53
  - Refrigerant Flow of Air Conditioning System
    53
  - Major Components and Location
    54
- Diagnosis
  
  55
- Recovery, Evacuation and Charging
  
  66
  - Refrigerant Recovery
    66
  - Evacuating and Charging
    66
- On-Vehicle Service
  
  67
  - A/C Condenser Assembly
    67
  - Receiver/Dryer
    68
  - Radiator (and Condenser) Cooling Fan Motor
    69
  - Cooling Unit
    70
  - A/C Evaporator Thermistor
    71
  - Expansion Valve
    72
  - Dual Pressure Switch
    72
  - A/C Switch
    72
  - Radiator (and Condenser) Cooling Fan Relay and Compressor Relay
    73
  - Compressor
    74
  - Magnet Clutch
    76
  - Disassembly of Compressor
    78
  - Checking Components
    82
  - Assembly of Compressor
    83
  - Assembly of Magnetic Clutch
    87
- Required Service Materials
  
  88
- Special Tools
  
  88
Section 3B Manual Rack and Pinion

101
- General Description
  
  102
- Diagnosis
  
  102
  - Diagnosis Table
    102
  - Steering Wheel Check
    102
  - Steering Rack Boot Check
    102
  - Tie Rod End Boot Check
    103
  - Steering Shaft Joint Check
    103
  - Tie Rod End Check
    103
- On-Vehicle Service
  
  103
  - Lubrication
    103
  - Manual Rack and Pinion Assembly
    105
    
    Removal
    105
    
    Disassembly
    106
    
    Inspection
    109
    
    Reassembly
    110
    
    Installation
    113
- Required Service Materials
  
  115
- Special Tool
  
  116
Section 3C Steering Wheel and Column

117
- 3C-2 Steering Wheel and Column
  118
- General Description
  118
- On-Vehicle Service
  
  119
- Diagnosis
  
  119
- Checking Steering Column Assembly and Lower Shaft for Accident Damage
  
  127
- Special Tool
  
  128
- Required Service Material
  
  128
Sectiond Front Suspension

129
- General Description
  
  130
- Diagnosis
  
  131
  - Diagnosis Table
    131
  - Stabilizer Bar And/Or Bushing Check
    131
  - Strut Assembly Check
    131
  - Suspension Control Arm and Bushing Check
    132
  - Suspension Control Arm Joint Check
    132
  - Wheel Disc, Nut and Bearing Check
    132
- On-Vehicle Service
  
  133
  - Strut Assembly
    133
  - Stabilizer Bar And/Or Bushings
    138
  - Wheel Hub, Wheel Stud and Wheel Bearing Outside Inner Race
    140
  - Suspension Control Arm/Bushing
    143
  - Knuckle and Bearing
    146
- Required Service Material
  
  149
- Special Tool
  
  149
Section 3E Rear Suspension

150
- General Description
  
  151
- Diagnosis
  
  152
- On-Vehicle Service
  
  154
  - Shock Absorber
    154
  - Leaf Spring
    155
  - Rear Axle
    157
  - Wheel Bearing and Wheel Stud
    160
- Required Service Materials
  
  164
- Special Tools
  
  164
Section 3E1 Rear Suspension

165
- General Description
  
  166
- Diagnosis
  
  168
- On-Vehicle Service
  
  170
  - Lateral Rod
    170
  - Rear Shock Absorber
    171
  - Trailing Arm and Bush
    171
  - Wheel Bearing and Wheel Stud
    173
  - Rear Axle
    177
- Special Tools
  
  181
- Required Service Materials
  
  181
Section 3F Wheels and Tires

182
- Maintenance and Minor Adjustments
  
  184
  - Tires
    184
  - Wheel Maintenance
    184
    
    Wheel Attaching Studs
    184
    
    Matched Tires and Wheels
    184
    
    Inflation of Tires
    185
    
    Tire Placard
    185
  - Tire Rotation
    185
- Diagnosis
  
  184
- On-Vehicle Service
  
  186
  - Service Operations
    186
    
    Metric Lug Nuts and Wheel Studs
    186
    
    Wheel Removal
    186
    
    Tire Mounting and Demounting
    186
    
    Tire Repair
    187
  - Balancing Wheels
    187
  - General Balance Procedures
    188
    
    Off-Vehicle Balancing
    188
    
    On-Vehicle Balancing
    188
- General Description
  
  190
Section 5 Brakes

197
- General Description
  
  198
  - Front Disc Brake Caliper Assembly
    199
  - Rear Drum Brake Assembly
    199
  - Master Cylinder Assembly
    199
- Diagnosis
  
  200
  - Diagnosis Table
    201
- On-Vehicle Service
  
  203
  - Brake Pedal Free Height Adjustment
    203
  - Brake Pedal Play Inspection
    203
  - Stop Light Switch Adjustment
    203
  - Excessive Pedal Travel Check
    203
  - Front Brake Pad Inspection
    204
  - Brake Disc Inspection
    204
  - Rear Drum Brake Shoe Adjustment
    204
  - Parking Brake Inspection and Adjustment
    205
  - Flushing Brake Hydraulic System
    205
  - Master Cylinder and Brake Fluid Level Inspection
    206
  - Brake Hose and Pipe Inspection
    206
  - Bleeding Brakes
    207
  - Brake Hose/Pipe and Parking Brake Cable
    209
  - Front Disc Brake
    211
    
    Brake Pad
    212
    
    Caliper Assembly
    214
    
    Brake Disc
    218
  - Rear Drum Brake
    219
    
    Brake Drum
    220
    
    Brake Shoe
    223
    
    Wheel Cylinder
    224
    
    Brake Back Plate
    226
  - Master Cylinder
    228
    
    Master Cylinder Reservoir
    228
    
    Master Cylinder Assembly
    229
- Required Service Materials
  
  233
- Special Tools
  
  233
Engine Mechanical (F8B Engine)

249
- General Description
  
  250
  - Engine
    250
  - Engine Lubrication
    251
- Engine Services Not Requiring Engine Removal
  
  252
- Dismounting Engine
  
  253
- Engine Disassembly
  
  256
- Inspection of Engine Components 6A-18
  
  266
  - Cylinder Head
    266
  - Rocker-Arm Shaft and Rocker Arms
    268
  - Valve Guides
    269
  - Valves
    269
  - Valve Seats
    270
  - Valve Springs
    272
  - Camshaft
    272
  - Cylinder Block
    273
  - Piston and Piston Rings
    274
  - Connecting Rods
    276
  - Connecting-Rod Big End Bearings
    276
  - Crankshaft
    278
  - Crankshaft Journal Bearings
    279
  - Flywheel
    280
  - Oil Seals
    280
  - Timing Belt and Timing Pulleys
    281
  - Oil Pump
    281
- Engine Reassembly
  
  282
  - Crankshaft
    282
  - Oil Seal Housing
    283
  - Oil Pump
    284
  - Piston and Piston Rings
    284
  - Connecting Rods
    286
  - Oil Pump Strainer
    286
  - Oil Pan
    286
  - Flywheel
    287
  - Cylinder Head
    287
  - Camshaft
    290
  - Rocker-Arm Shafts
    290
  - Crankshaft Timing Belt Guide
    291
  - Camshaft and Crankshaft Timing Belt Pulleys
    291
  - Timing Belt
    291
  - Distributor Gear Case
    293
  - Generator
    293
  - Clutch Disc and Cover
    293
  - Distributor
    293
  - Valve Lash (Clearance) Adjustment
    293
- Mounting Engine
  
  294
- Maintenance Services
  
  296
  - Water Pump Belt
    296
  - Ignition Timing
    296
  - Valve Clearance (Lash)
    296
  - Oil Pump Discharge Pressure Measurement
    298
  - Compression Pressure Measurement
    299
  - Vacuum Measurement
    300
  - Engine Oil
    301
  - Engine Oil Filter
    301
  - Engine Coolant
    301
  - Exhaust Line and Muffler
    301
  - Oil Filter Cap
    301
- Required Service Materials
  
  302
- Special Tools
  
  302
(F8D Engine)

304
- General Description
  
  305
  - Engine
    305
  - Engine Lubrication
    306
- On-Vehicle Service
  
  307
  - Compression Check
    307
  - Engine Vacuum Check
    308
  - Oil Pressure Check
    309
  - Valve Lash (Clearance)
    311
  - Air Cleaner Filter
    312
  - Cylinder Head Cover
    313
  - Throttle Body and Intake Manifold
    314
  - Exhaust Manifold
    316
  - Timing Belt and Belt Tensioner
    318
  - Oil Pan and Oil Pump Strainer
    323
  - Oil Pump
    326
  - Rocker Arms, Rocker Arm Shaft and Camshaft
    329
  - Valves and Cylinder Head
    335
  - Piston, Piston Rings, Connecting Rods and Cylinders
    345
- Unit Repair Overhaul
  
  354
  - Engine Assembly
    354
  - Main Bearings, Crankshaft and Cylinder Block
    355
- Required Service Materials
  
  367
- Special Tools
  
  367
Section 6B Engine Cooling

369
- General Description
  
  370
  - Cooling System Circulation
    370
- Diagnosis
  
  371
- Maintenance
  
  372
  - Coolant
    372
  - Coolant Level
    373
  - Cooling System Service
    373
  - Cooling System Flush and Refill
    374
  - Water Pump Belt Tension
    375
- On-Vehicle Service
  
  376
  - Cooling System Draining
    376
  - Cooling Water Pipes or Hoses
    376
  - Thermostat
    377
  - Water Pump Belt
    378
  - Radiator
    379
  - Water Pump
    380
- Required Service Materials
  
  382
Section 6C Engine Fuel

383
- General Description
  384
  - Fuel Tank
    384
  - Fuel Pump
    384
  - Fuel Filter
    384
  - Fuel Filler Cap
    384
  - On-Vehicle Service
    385
  - Fuel Lines
    385
  - Fuel Pipe
    386
  - Fuel Filler Cap
    386
  - Fuel Filter
    387
  - Fuel Tank
    387
  - Fuel Pump
    446
Section 6F Ignition System

470
- General Description
  
  471
  - Components
    471
  - System Wiring
    472
- Diagnosis
  
  473
  - Diagnostic Flow Table
    473
  - Ignition Spark Test
    475
- On-Vehicle Service
  
  475
  - High-Tension Cords
    475
  - Spark Plugs
    476
  - Noise Suppressor
    477
  - Igniter
    477
  - Ignition Coil
    478
  - Distributor
    478
  - Ignition Timing
    480
- Distributor Unit
  
  482
- Special Tools
  
  484
Section 6G Cranking System

485
- General Description
  
  486
  - Cranking Circuit
    486
  - Starting Motor Circuit
    486
- Diagnosis
  
  487
- Unit Repair Overhaul
  
  489
  - Dismounting and Remounting
    490
  - Disassembly
    490
  - Reassembly
    491
  - Inspection
    492
    
    Plunger
    492
    
    Magnetic Switch
    492
    
    Brush
    493
  - Brush Holder
    493
  - Armature
    493
  - Yoke
    494
  - Over-Running Clutch
    494
  - Performance Test
    495
    
    Pull-In Test
    495
    
    Hold-In Test
    495
    
    Pinion Return Test
    496
    
    No-Load Performance Test
    496
- Required Service Material
  
  497
- Special Tool
  
  497
- Specifications
  
  497
Section 6H Charging System

498
- General Description
  
  499
  - Battery
    499
  - Generator
    501
- Diagnosis
  
  503
  - Battery
    503
  - Generator
    504
- On-Vehicle Service
  
  507
  - Battery
    507
    
    Jump Starting in Case of Emergency with Auxiliary (Booster) Battery
    507
    
    Removal
    508
    
    Handling
    508
    
    Installation
    508
  - Generator
    509
    
    Removal
    509
    
    Installation
    509
  - Generator (Water Pump) Belt
    510
    
    Belt Tension Inspection
    510
    
    Removal
    510
    
    Installation
    510
- Unit Repair Overhaul
  
  511
  - Generator
    511
    
    Disassembly
    512
    
    Inspection
    514
    
    Replace Brush
    516
    
    Assembly
    517
- Specifications
  
  519
Section 7A1 Manual Transmission (5-Speed)

550
- General Description
  
  551
- Diagnosis
  
  555
- On-Vehicle Service
  
  556
  - Oil Change
    556
  - Differential Side Oil Seal
    557
  - Gear Shift Control
    558
- Unit Repair Overhaul
  
  559
  - Dismounting/Remounting
    559
  - Disassembling Unit
    559
    
    Fifth Gears
    559
    
    Gear Shifter, Main Shaft and Countershaft
    560
    
    Right Case
    562
  - Sub Assembly Service
    564
    
    Right Case
    564
    
    Left Case
    565
    
    Input Shaft Assembly
    565
    
    Countershaft Assembly
    568
    
    Gear Shifter
    571
    
    Differential Assembly
    573
  - Assembling Unit
    575
    
    Differential to Left Case
    575
    
    Fifth Gears
    578
- Required Service Materials
  
  582
- Special Tools
  
  583
  - General Description
    586
  - On-Vehicle Service Maintenance Service
    589
    
    Clutch Pedal
    589
    
    Clutch Cable
    590
  - Unit Repair Overhaul
    591
  - Clutch Cover, Clutch Disc and 7C- 4 Flywheel
    591
  - Required Service Materials
    598
  - Special Tools
    598
Section 8 Body Electrical System

599
- General Description
  
  600
  - Cautions in Servicing
    600
  - Wire Color Symbols
    602
  - Combination Meter
    603
- Diagnosis
  
  604
  - Headlight
    604
  - Turn Signal and Hazard Warning Lights
    604
  - Clearance, Tail and License Plate Lights
    604
  - Back-Up Light
    605
  - Brake Lights
    605
  - Fuel Meter and Fuel Gauge Unit
    605
  - Engine Coolant Temp. (ECT) Meter and ECT Sensor
    605
  - Oil Pressure Light
    605
  - Brake and Parking Brake Warning Light
    606
  - Windshield Wiper and Washer
    606
  - Front Wiper and Washer
    606
  - Interior Light
    606
  - Horn
    606
- On-Vehicle Service
  
  607
  - Headlight
    607
  - Turn Signal and Hazard Warning Light
    609
  - Ignition Switch
    610
  - Combination Meter
    610
  - Fuel Meter/Fuel Gauge Unit
    611
  - Engine Coolant Temperature (ECT) Meter and Sensor Unit
    612
  - Oil Pressure Warning Light
    613
  - Brake and Parking Brake Warning Light
    613
  - Wipers and Washers
    614
  - Door Switch
    617

MARUTI SUZUKI 800 Owner's Manual (120 pages)

Brand: MARUTI SUZUKI | Category: Automobile | Size: 1 MB

Table of Contents

1
- Maintenance Service Record
  5
- Warranty Policy
  7
Before Driving

13
- Fuel Recommendation
  14
- Immobilizer Key (if Equipped)
  15
- Keys
  15
- Door Locks
  16
- Mirrors
  18
- Windows
  18
- Front Seat Adjustment
  19
- Adjustable Head Restraints (if Equipped)
  20
- Seat Belts
  20
Steering Column Controls

25
- Ignition Switch
  26
- Lighting/Turn Signal Control Lever
  27
- Hazard Warning Switch
  28
- Windscreen Wiper and Washer Lever
  29
- Horn
  30
Instrument Panel

31
- Instrument Cluster
  32
- Instrument Panel
  32
- Warning and Indicator Lights
  33
- Immobilizer System Light (if Equipped)
  35
- Speedometer/Odometer
  35
- Ashtray (if Equipped)
  36
- Fuel Gauge
  36
- Temperature Gauge
  36
- Glove Box
  37
- HEADLIGHT LEVELING SWITCH (if Equipped)
  37
- Heating System (if Equipped)
  39
- System Operating Instructions
  40
- Air Conditioning System (if Equipped)
  43
- System Operating Instructions
  43
Other Controls and Equipment

45
- Parking Brake Lever
  46
- Gear Lever
  47
- Pedals
  47
- Fuel Filler Cap
  48
- Folding Rear Seats
  49
- Assist Grips
  50
- Interior Light Switch
  50
- Sun Visor
  50
- Bonnet
  51
- High Mount Stop Lamp (if Equipped)
  52
- Tyre Changing Tools
  52
Operating Your Vehicle

53
- Daily Inspection Checklist
  54
- Exhaust Gas Warning
  54
- Starting the Engine
  55
- Using the Transmission
  56
- Braking
  57
- Running-In
  57
- Catalytic Converter
  58
- Improving Fuel Economy
  59
- Trailer Towing
  59
- Driving Tips and Safe Driving
  61
Inspection and Maintenance

67
- Periodic Maintenance Schedule
  68
- Drive Belt
  73
- Engine Oil and Filter
  73
- Gear Oil
  76
- Engine Coolant
  78
- Air Cleaner
  79
- Windscreen Washer Fluid
  79
- Spark Plugs
  80
- Brakes
  81
- Clutch Pedal
  83
- Steering
  83
- Tyres
  84
- Battery
  87
- Fuses
  87
- Bulb Replacement
  89
- Wiper Blades
  92
Emergency Service

93
- Jacking Instructions
  94
- Jump Starting Instructions
  95
- Emergency Remedies
  97
- Towing
  97
- Warning Triangle
  98
- Body Work Care
  101
- General Information
  105
For Lpg Kit Fitted Vehicle (Liquid Petroleum Gas)

107
- For Lpg Kit Fitted Vehicle
  107
- (Liquid Petroleum Gas)
  108
- Location of LPG System and Major Components
  108
- Introduction to LPG
  109
- Safety Precautions (Do's and Dont's)
  110
- LPG Level Indicator
  111
- Manual Shut off Valve
  111
- Vehicle Starting Modes
  111
- Auto Mode
  112
- Petrol Mode
  112
- Forced LPG Mode
  113
- Spare Wheel Location
  113
- Spare Wheel Removal Procedure
  113
- LPG Filling
  114
- Periodic Maintenance Schedule
  114
- Petrol Tank Capacity
  114
- Kit Identification
  116
- Maintenance (Fuse)
  116
- Scrapping of LPG Tanks after Expiry Date
  117
- Specification
  119

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MARUTI SUZUKI 800 Manuals

MARUTI SUZUKI 800 Service Manual (644 pages)

Table of Contents

Section 0A General Information

How to Use this Manual

Precautions

Identification Information

Vehicle Lifting Points

Abbreviations May be Used in this Manual

Metric Information

Maintenance and Lubrication

Periodic Maintenance Schedule

Maintenance Service

Recommended Fluids and Lubricants

Section 1A Heater (Optional) and Ventilation

General Description

Heater (Optional) and Ventilation

Diagnosis

On Vehicle Service

Section 1B Air Conditioning (Optional)

General Description

Diagnosis

Recovery, Evacuation and Charging

On-Vehicle Service

Required Service Materials

Special Tools

Section 3B Manual Rack and Pinion

General Description

Diagnosis

On-Vehicle Service

Required Service Materials

Special Tool

Section 3C Steering Wheel and Column

On-Vehicle Service

Diagnosis

Checking Steering Column Assembly and Lower Shaft for Accident Damage

Special Tool

Required Service Material

Sectiond Front Suspension

General Description

Diagnosis

On-Vehicle Service

Required Service Material

Special Tool

Section 3E Rear Suspension

General Description

Diagnosis

On-Vehicle Service

Required Service Materials

Special Tools

Section 3E1 Rear Suspension

General Description

Diagnosis

On-Vehicle Service

Special Tools

Required Service Materials

Section 3F Wheels and Tires

Maintenance and Minor Adjustments

Diagnosis

On-Vehicle Service

General Description

Section 5 Brakes

General Description

Diagnosis

On-Vehicle Service

Required Service Materials

Special Tools

Engine Mechanical (F8B Engine)

General Description

Engine Services Not Requiring Engine Removal

Dismounting Engine

Engine Disassembly

Inspection of Engine Components 6A-18

Engine Reassembly

Mounting Engine

Maintenance Services

Required Service Materials

Special Tools

(F8D Engine)

General Description