Suzuki LJ80V Manuals

Manuals and User Guides for Suzuki LJ80V. We have 1 Suzuki LJ80V manual available for free PDF download: Service Manual

Suzuki LJ80V Service Manual (296 pages)

Brand: Suzuki | Category: Automobile | Size: 27.74 MB

Table of Contents
2
General: Contents
3
Body and Chassis of Suzuki LJ80 and LJ80V
4
LJ80 and LJ80V Chassis with Engine
5
Outline Dimensions LJ80
7
Outline Dimensions LJ80V
8
Specifications
9
Locations of Body Number and Engine Number
12
Standard Shop Practices
13
Engine Cylinder Numbers
14
Special Tools
15
Required Materials
19
Troubleshooting: Contents
21
Engine Troubleshooting
22
Poor Starting
22
Not Enough Power
23
Sudden Drop of Speed in High Speed Cruise
24
Engine Not Responding Quickly to Pedal Control in Picking up Speed
24
Erratic Idling
25
Abnormal Detonation
25
Engine Overheating
26
Abnormal Engine Noise
26
High Fuel Consumption
27
Excessive Engine Oil Consumption
27
Carburetor Troubleshooting
28
Exhaust and Muffler Troubleshooting
28
Clutch Troubleshooting
28
Transmission Troubleshooting
29
Differentials Troubleshooting
30
Propeller Shafts Troubleshooting
31
Brakes Troubleshooting
31
Front Suspension and Steering System Troubleshooting
32
Starting Motor Troubleshooting
33
Alternator Troubleshooting
34
Wiper Motor Troubleshooting
35
Fuel Meter Troubleshooting
36
Turn Signal Lights Troubleshooting
36
Speedometer Troubleshooting
37
Water Temperature Meter Troubleshooting
37
Oil Pressure Warning Light Troubleshooting
37
Charge Warning Light Troubleshooting
38
Horn Troubleshooting
38
Engine: Contents
39
Engine: Description
40
Engine Features
41
Blowby Gas Recycling System
42
Engine Services Not Requiring Engine Removal
43
Dismounting the Engine
44
Engine Disassembly
45
Engine Maintenance Service
53
Cylinder Head
53
Rocker Arm Shaft and Rocker Arms
54
Valve Guides
55
Valves
56
Valve Seats
57
Valve Springs
59
Engine Reassembly
60
Tightening Torque Data
60
Oil Seal Housing
61
Oil Pump
62
Piston and Piston Rings
62
Connecting Rods
63
Oil Pump Strainer
64
Oil Pan
64
Flywheel, Cylinder Head
65
Camshaft
66
Rocker Arm Shafts
67
Water Inlet Pipe
68
Crankshaft Timing Belt Guide
68
Cylinder Head Front Side Case
68
Camshaft Timing Belt Pulley
69
Timing Belt (Valve Timing Adjustment)
69
Valve Clearance Adjustment
70
Distributor, Distributor Gear Case
71
Alternator
71
Clutch
72
Engine Inspection and Adjustments
73
Timing Belt
74
Measuring/Adjusting Valve Clearance
74
Oil Pimp Discharge Pressure Measurement
75
Vacuum Measurement
75
Compression Pressure Measurement
75
Engine Oil, Oil Filter, Coolant
76
Exhaust Line and Muffler
76
Oil Filler Cap
76
Crankcase Ventilation Hose
76
Engine Lubrication
77
Oil Pump Disassembly, Inspection
78
Oil Pump Reassembly
79
Checking Oil Pressure
80
Oil Filter Servicing
80
Oil Pump Strainer Servicing
80
Engine Oil Servicing
81
Oil Level Gauge
81
Carburetor: Contents
82
Carburetor Description, Specifications
83
Carburetor Circuit Diagram
84
Carburetor Operation
85
Float Chamber
85
Slow/High Speed Mixture
85
Acceleration Power System
85
Inspecting and Adjusting
86
Jets
86
Choke Valve
86
Needle Valve
86
Accelerator and Choke Cables
87
Fuel Tank Cap
87
Fuel Level Adjustment
87
Fuel Hose
87
Idle Speed and Idle Mixture Adjustment
88
Air Cleaner, Fuel Pump and Fuel Filter: Contents
90
Air Cleaner Description
91
Air Cleaner Element Inspection and Servicing
91
Use of the Selector Level
92
Fuel Pump
93
Fuel Filter Servicing and Installation
94
Engine Cooling System: Contents
96
Engine Cooling System: Description
97
Cooling Water Circuit
97
Engine Cooling System Removal
98
Coolant Draining
98
Radiator Removal
98
Removal of Cooling Water Pipers, Cooling Fan Removal
98
Water Pump Removal
99
Water Reservoir Tank
99
Thermostat
99
Radiator Filler Cap
99
Requirements on Coolant
100
Water Pump
100
Golden Cruiser 1200 "Anti-Freeze and Summer Coolant" - Its Effects and Use
101
Water Temperature Gauge
102
Anti-Freeze Proportioning Chart
102
Cooling System Services
103
Thermostat, Fan Belt
103
Coolant Level
104
Radiator
104
Water Hoses
104
Important Re-Installing Steps
105
Filling up the Cooling System
105
Car Heater: Contents
106
Car Heater: Description
107
Car Heater: Electrical Circuit
107
Heater Services
108
Fan Resistor
108
Fan Switch
108
Ignition System: Contents
110
Ignition System: Description
111
Distributor
112
Ignition Coil
113
Spark Plugs
113
Timing Advancer
113
Maintenance Services
114
Distributor Cap, Spark Plugs
114
Distributor Driven Gear
114
Contact Point Faces
114
Checking the Primary Circuit for Fault
115
Ignition Coil, Condenser
115
Important Reminders for Reassembly and Installation: Distributor
116
Ignition Timing Specifications
117
Ignition Timing Checking Methods
117
Important Reminders for Reassembly and Installation: High Tension Cords
117
Replacement of Distributor Driven Gear
119
Starter Motor: Contents
120
Starter Motor: Description, Specification
121
Cranking Action
122
Starting up the Motor
122
Pinion Meshing with the Ring Gear
122
Starter Motor Removal
123
Engine Cranking
123
Terminating Cranking Operation
123
Starter Motor Disassembly
124
Checking the Field Coils
125
Servicing the Communicator
125
Checking the Armature
125
Testing the Magnetic Switch
126
Servicing the Brush Holders
126
Servicing the Brushes
126
Important Reminders for Starter Motor Reassembly
127
Charging System: Contents
128
Charging System: Description
129
Charging Operation
130
Alternator Description
132
Alternator Data and Specification
133
Alternator Removal/Disassembly
133
Testing the Rotor for Open Circuit
134
Testing the Rotor for Grounding
134
Stator, Brushes, Rectifier - Servicing
135
Alternator Load Performance
135
Alternator Regulator: Specifications, Maintenance Services
136
Guide on Regulator Diagnosis
138
Main Fuse
139
Battery Specifications
139
Care of the Battery
140
Clutch: Contents
142
Clutch: Description
143
Clutch: Removal
144
Clutch Maintenance Services
144
Clutch Disc Facing Surface Condition
144
Clutch Facing Wear
144
Backlash in Disc Serration Fit
145
Release Bearing
145
Inspect Shaft Bearing and Oil Seal
145
Clutch Cover
145
Clutch Disc and Clutch Cover Installation
146
Clutch Pedal Height
146
Clutch Pedal Play
146
Input Shaft Bearing
147
Clutch Release Bearing Retainer
147
Clutch Release Arm
147
Gearshifting Control: Contents
148
Gearshifting Control: Description
149
Gearshifting Control: Removal
150
Gearshift Lever Adjustment
150
Guide Plate Inspection
150
Gearshifting Control Installation
151
Transmission: Contents
152
Transmission: Description
153
Flow of Drive through Transmission
154
Transmission Gear Ratio
156
Transmission Dismounting, Disassembly
156
Removing the Countershaft
157
Removing the Main Shaft and Input Shaft
157
Removing the Shifter Fork Shaft and Forks
158
Transmission: Maintenance Services
159
Reverse Gears and Idle Gear
159
Countershaft and Its Bearings
159
Input Shaft
160
Combination of Gear and Synchronizer Ring
160
Chamfered Tooth Ends of Ring and Sleeve
160
Synchronizer Rings
161
Transmission: Important Step in Installation
162
Tightening Torque
162
Input Shaft and Main Shaft
162
Extension Case Bush
162
Shifter Forks and Shafts
163
Reverse Gears and Idle Gear, Extension Case Oil Seal
164
Input Shaft and Main Shaft Installation, Putting Together Upper and Lower Cases
164
Transmission Oil
165
Transfer Gear Box: Contents
166
Transfer Gear Box: Description
167
Selective Flows of Transfer Drive
168
2-Wheel Drive
168
4-Wheel Drive High
168
Gear Ratio Data
169
Transfer Gear Box Removal
169
4-Wheel Drive Low
169
Transfer Gear Box Disassembly
170
Universal Joint Yoke Flanges
170
Center Brake
170
Speedometer Driven Gear, Transfer Gear Control Lever
170
Upper Transfer Cover
171
Transfer Front Case, Countershaft
171
Shifter Fork Shafts
172
Transfer Gear Box Maintenance Services
173
Gear Teeth
173
Output Rear Shaft
173
Locating Spring
173
Transfer Gear Box Important Steps in Installation
174
Parking Brake
174
Output Rear Shaft, Shifter Fork Shafts and Forks
175
Locating Spring and Balls for Shifter Fork Shafts
175
Counter Gear Needle Bearings
176
Counter Gear Assembly
176
Counter Gear Stopper Pin
176
Transfer Case Covers
177
Lubricating Oil for Transfer Gear
177
Propeller Shafts: Contents
178
Propeller Shafts: Description
179
Propeller Shafts: Removal
180
Propeller Shafts: Maintenance Services
180
Universal Joint Noise
180
Propeller Shafts Installation
183
Differential: Contents
184
Differential: Description
185
Differential: Removal
186
Differential Disassembly
188
Differential Maintenance Services
189
Side Gear Backlash
189
Determination of Shim Thickness for Bevel Pinion
190
Bevel Pinion Bearing Preload Adjustment
191
Bevel Gear Backlash Adjustment
192
Pinion-To-Gear Tooth Contact Pattern Check and Adjustment
193
Differential Reassembly Instructions
195
Drive Bevel Gear Bolts
195
Bevel Pinion Bearings
195
Differential Side Bearings
195
Side Bearing Caps
196
Differential Gear Oil
196
Suspension: Contents
198
Suspension: Description
199
Barfield Joint Construction and Operation
200
Removal of Front Wheel and Kuckle
201
Suspension: Maintenance Services
202
Barfield Joint
202
Kingpins
202
Oil Seal
203
Suspension: Important Steps in Reassembly
204
Wheel Spindle, Knuckle
204
Shock Absorbers and Leaf Spring Specifications
205
Shock Absorbers and Leaf Spring Tips on Installation
206
Steering System: Contents
207
Steering System: Description, Specifications and Data
208
Steering Gear Box Construction and Operation
209
Steering Handwheel, Steering Shaft, Gear Box Removal
210
Steering System: Maintenance Services
211
Steering Handwheel Play
211
Steering Gear Box
211
Steering Rubber Joint
212
Wheel and Hub Nuts
212
Steering Tie Rod Lever and Tie Rod
212
Tires
212
Steering System: Important Step in Reassembly
213
Tie Rod Turnbuckles, Steering Handwheel
213
Steering Column Cover Clearances
214
Wheel Alignment
214
Alignment Service Data
214
Brakes: Contents
215
Brakes: Description
216
Tandem Master Cylinder
217
Tandem Master Cylinder Operation
217
Front/Rear Brake Construction
219
Center Brake Construction
219
Brake: Maintenance Services
220
Wheel Cylinder Construction
220
Brake Drum
220
Brake Shoes, Brake Pipes, Air Purging
221
Master Cylinder and Wheel Cylinders
221
Brake Fluid, Brake Pedal
222
Brake Shoe Clearance Adjustment
222
Parking Brake Lever
222
Parking Brake Cable
223
Brake Hoses and Pipes
223
Door: Contents
224
Door: Description
225
Door Assembly (LJ80V)
226
Door Inspection and Adjustments (LJ80V)
228
Outside Door Handle
228
Door Lock Striker
228
Window Regulator
228
Door Window Glass
229
Body Electrical Equipment: Contents
230
Wiring Diagram
231
Headlight Wiring Circuit
233
Headlight Beam Setting
233
Headlight Beam Maintenance
234
Turn Signal Light and Hazard Warning Light: Circuit Description
235
Windshield Wiper Motor Circuit Description
236
Turn Signal Light and Hazard Warning Light: Inspection
236
Windshield Wiper Motor Maintenance
237
Fuel Gauge: Circuit Description, Inspection
238
Service Data and Maintenance Schedule: Contents
239
Engine Service Data
240
Cooling System Service Data
243
Differential Service Data
243
Suspension Service Data
244
Steering System Service Data
245
Tire Service Data
246
Brake Service Data
247
Electrical Service Data
248
Capacity Service Data
252
Tightening Torque: Engine
253
Tightening Torque: Transmission
257
Tightening Torque: Transfer Gear Box
258
Tightening Torque: Differential
260
Tightening Torque: Suspension
261
Tightening Torque: Steering
263
Tightening Torque: Brake
265
Periodic Maintenance
268
Lj81
270
LJ81 Specifications
272
Camshaft Timing Belt
279
Transfer Input Shaft Bearing Retainer Shim
281
Input Shaft Bearing Retainer
282
Air Cleaner
289
Starting Motor
290
Important Reminder for Starter Motor Reassembly
294
Shift Lever, Yoke
295
Armature
295
Starter Magnetic Switch
295

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