Suzuki RA410 Manuals

Manuals and User Guides for Suzuki RA410. We have 1 Suzuki RA410 manual available for free PDF download: Manual

Suzuki RA410 Manual (761 pages)

Brand: Suzuki | Category: Automobile | Size: 14.94 MB

Section 0A General Information

4
- Table of Contents
  4
- How to Use this Manual
  
  5
- Precautions
  
  6
- Identification Information
  
  18
- Warning, Caution and Information Labels
  
  19
- Vehicle Lifting Points
  
  20
- Abbreviations May be Used in this Manual
  
  22
- Metric Information
  
  24
Maintenance and Lubrication

25
- Maintenance Schedule
  
  26
- Maintenance Service
  
  29
  - Engine
    29
  - Ignition System
    33
  - Fuel System
    33
  - Emission Control System
    34
  - Brake
    35
  - Chassis and Body
    36
  - Final Inspection
    41
- Recommended Fluids and Lubricants
  
  42
Section 1A Heater and Ventilation

43
- General Description
  
  44
  - Heater Unit
    45
  - Air Inlet Box
    46
  - Heater Control Lever Assembly
    46
- Diagnosis
  
  47
  - Diagnosis Table
    47
  - Wiring Circuit
    47
- On Vehicle Service
  
  48
  - Blower Motor
    48
  - Blower Motor Resistor
    48
  - Heater Control Lever Assembly
    49
  - Blower Fan Switch
    50
  - Heater Unit
    51
  - Ventilation Louver
    52
Section 1B Air Conditioning (Optional)

53
- General Description
  
  54
  - Refrigerant Flow of Air Conditioning System
    54
  - Major Components and Location
    55
- Diagnosis
  
  56
- Recovery, Evacuation and Charging
  
  64
  - Refrigerant Recovery
    64
  - Evacuating and Charging
    64
- On-Vehicle Service
  
  65
  - A/C Condenser Assembly
    65
  - Receiver/Driver
    66
  - Radiator (and Condenser) Cooling Fan Motor
    67
  - Cooling Unit
    68
  - A/C Evaporator Thermistor
    69
  - Expansion Valve
    70
  - Dual Pressure Switch
    70
  - A/C Switch
    70
  - Radiator (and Condenser) Cooling Fan Relay
    71
  - Compressor
    71
  - Magnet Clutch
    73
- Performance Test
  
  78
- Special Tools
  
  81
Section 3B Manual Rack and Pinion

93
- Diagnosis
  
  94
  - Diagnosis Table
    94
  - Steering Wheel Check
    94
  - Steering Rack Boot Check
    94
  - Tie Rod End Boot Check
    95
  - Steering Shaft Joint Check
    95
  - Tie Rod End Check
    95
- General Description
  
  94
- On-Vehicle Service
  
  95
  - Lubrication
    95
  - Manual Rack and Pinion Assembly
    97
- Required Service Materials
  
  107
- Special Tools
  
  107
Section 3B1 Electrical Power Steering (P/S) System

108
- General Description
  
  109
  - Components
    109
  - Wiring Diagram
    110
- Diagnosis
  
  111
- On-Vehicle Service
  
  128
  - P/S Control Module
    128
  - Torque Sensor
    128
  - Motor and Clutch
    129
  - Steering Column Assembly
    129
Section 3C Steering Wheel and Column

130
- Diagnosis
  
  132
  - Inspection and Repair Required after Accident
    132
- On-Vehicle Service
  
  132
  - Service Precautions (for Vehicle with Air Bag System)
    132
    
    Disabling Air Bag System
    132
    
    Disposal
    132
    
    Enabling Air Bag System
    132
    
    Handling and Storage
    132
    
    Service and Diagnosis
    132
  - Driver Air Bag (Inflator) Module (for Vehicle with Air Bag System)
    133
  - Steering Wheel
    134
  - Centering Contact Coil (for Vehicle with Air Bag System)
    137
  - Combination Switch
    137
  - For Vehicle with Air Bag System
    137
  - Steering Column Assembly
    140
  - Steering Lock Assembly (Ignition Switch)
    145
  - Steering Lower Shaft
    146
- General Description
  
  132
- Checking Steering Column Assembly and Lower Shaft for Accident Damage
  
  147
- Required Service Material
  
  148
- Special Tool
  
  148
Sectiond Front Suspension

149
- Diagnosis
  
  152
  - Diagnosis Table
    152
  - Stabilizer Bar And/Or Bushing Check
    152
  - Strut Assembly Check
    152
  - Suspension Control Arm/Steering Knuckle Check
    153
  - Suspension Control Arm Bushing Check
    153
  - Suspension Control Arm Joint Check
    153
    
    Front Suspension Fasteners Check
    153
    
    Wheel Disc, Nut and Bearing Check
    153
- General Description
  
  152
- On-Vehicle Service
  
  155
  - Strut Assembly
    155
  - Stabilizer Bar And/Or Bushing
    158
  - Wheel Hub and Steering Knuckle
    160
  - Suspension Control Arm/Bushing
    164
- Required Service Material
  
  167
- Special Tools
  
  167
Section 3E Rear Suspension

168
- General Description
  
  169
- Diagnosis
  
  170
- On-Vehicle Service
  
  172
  - Lateral Rod
    172
  - Rear Shock Absorber
    173
  - Coil Spring
    173
  - Bump Stopper
    175
  - Spring Upper Seat
    176
  - Trailing Arm
    176
  - Rear Axle
    179
  - Wheel Bearing and Wheel Stud
    183
Section 4A Front Drive Shaft

193
- General Description
  194
  - Component
    194
- Diagnosis
  195
  - Diagnosis Table
    195
- On-Vehicle Service
  196
  - Drive Shaft Assembly
    196
- Required Service Materials
  204
- Special Tool
  204
Engine Mechanical

260
- General Description
  
  261
- On Vehicle Service
  
  263
  - Compression Check
    263
  - Engine Vacuum Check
    265
  - Oil Pressure Check
    266
  - Valve Lash (Clearance)
    268
  - Air Cleaner Element
    270
  - Air Cleaner Assembly and Resonator
    271
  - Cylinder Head Cover
    272
  - Throttle Body and Intake Manifold
    274
  - Oil Pan and Oil Pump Strainer
    277
  - Exhaust Manifold
    280
  - Crankshaft Pulley and Oil Seal
    282
  - Timing Chain Cover
    284
  - Oil Pump
    288
  - Timing Chain and Chain Tensioner
    291
  - Camshafts, Tappets and Shims
    296
  - Valves and Cylinder Head
    302
  - Piston, Piston Rings, Connecting Rods
    313
- Unit Repair Overhaul
  
  322
  - Engine Assembly
    322
  - Main Bearings, Crankshaft and Cylinder Block
    328
- Special Tools
  
  339
- Required Service Material
  
  340
Section 6B Engine Cooling

341
- General Description
  
  342
  - Cooling System Circulation
    342
- Diagnosis
  
  343
- Maintenance
  
  344
  - Coolant
    344
  - Coolant Level
    345
  - Cooling System Service
    345
  - Cooling System Flush and Refill
    346
  - Water Pump Belt Tension
    347
- On-Vehicle Service
  
  348
  - Cooling System Draining
    348
  - Cooling Water Pipes or Hoses
    348
  - Thermostat
    349
  - Water Pump Belt
    350
  - Radiator
    351
  - Water Pump
    352
- Required Service Materials
  
  354
- Special Tools
  
  434
Section 6H Charging System

470
- Battery
  
  471
  - General Description
    471
  - Care of Battery
    471
  - Diagnosis
    472
  - On-Vehicle Service
    474
    
    Jump Starting in Case of Emergency
    474
    
    Handling
    475
    
    Installation
    475
    
    Removal
    475
- Generator General Description
  
  476
  - Diagnosis
    477
  - On-Vehicle Service
    480
    
    Removal
    480
    
    Disassembly
    481
    
    Inspection
    484
    
    Replace Brush
    486
    
    Assembly
    487
    
    Installation
    489
- Specifications
  
  489
Section 8 Body Electrical System

617
- General Description
  
  619
  - Cautions in Servicing
    619
  - Wire Color Symbols
    621
  - Combination Meter
    622
- Diagnosis
  
  623
  - Headlight
    623
  - Turn Signal and Hazard Warning Lights
    623
  - Clearance, Tail and License Plate Lights
    623
  - Back-Up Light
    624
  - Brake Lights
    624
  - Speedometer and VSS
    624
  - Fuel Meter and Fuel Level Sensor (Gauge Unit)
    624
  - Engine Coolant Temp. (ECT) Meter and ECT Sensor
    625
  - Oil Pressure Light
    625
  - Brake and Parking Brake Warning Light
    625
  - Rear Window Defogger (if Equipped)
    625
  - Wipers and Washers
    626
    
    Front Wiper and Washer
    626
    
    Rear Wiper and Washer (if Equipped)
    626
  - Power Window Control System (if Equipped)
    626
  - Cigarette Lighter (if Equipped)
    626
  - Interior Lights
    627
  - Horn
    627
  - Ignition Key Remainder/Light Remainder Warning Buzzer
    627
- On-Vehicle Service
  
  628
  - Headlight
    628
  - Turn Signal and Hazard Warning Light
    631
  - Ignition Switch
    632
  - Combination Meter
    632
  - Speed Meter/Sensor
    633
  - Fuel Meter/Fuel Level Sensor (Gauge Unit)
    633
  - Engine Coolant Temperature Meter and Sensor for Meter
    634
  - Oil Pressure Warning Light
    635
  - Brake and Parking Brake Warning Light
    635
  - Rear Window Defogger (if Equipped)
    635
  - Wipers and Washers
    637
  - Power Window Control System (if Equipped)
    641
  - Door Switch
    642
  - Stop Lamp Switch
    642
  - Ignition Key Remainder/Light Remainder Warning Buzzer
    642
    
    General Description
    688
    
    Diagnosis
    689
    
    Seat Belt
    689
    
    Seat Belt Pretensioner (if Equipped)
    689
    
    On-Vehicle Service
    690
    
    Service Precautions
    690
    
    Front Seat Belt Without Pretensioner
    691
    
    Front Seat Belt with Pretensioner
    693
    
    Rear Seat Belt
    695
    
    Air Bag System
    696

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Suzuki RA410 Manuals

Suzuki RA410 Manual (761 pages)

Table of Contents

Section 0A General Information

How to Use this Manual

Precautions

Identification Information

Warning, Caution and Information Labels

Vehicle Lifting Points

Abbreviations May be Used in this Manual

Metric Information

Maintenance and Lubrication

Maintenance Schedule

Maintenance Service

Recommended Fluids and Lubricants

Section 1A Heater and Ventilation

General Description

Diagnosis

On Vehicle Service

Section 1B Air Conditioning (Optional)

General Description

Diagnosis

Recovery, Evacuation and Charging

On-Vehicle Service

Performance Test

Special Tools

Section 3B Manual Rack and Pinion

Diagnosis

General Description

On-Vehicle Service

Required Service Materials

Special Tools

Section 3B1 Electrical Power Steering (P/S) System

General Description

Diagnosis

On-Vehicle Service

Section 3C Steering Wheel and Column

Diagnosis

On-Vehicle Service

General Description

Checking Steering Column Assembly and Lower Shaft for Accident Damage

Required Service Material

Special Tool

Sectiond Front Suspension

Diagnosis

General Description

On-Vehicle Service

Required Service Material

Special Tools

Section 3E Rear Suspension

General Description

Diagnosis

On-Vehicle Service

Section 4A Front Drive Shaft

Engine Mechanical

General Description

On Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Material

Section 6B Engine Cooling

General Description

Diagnosis

Maintenance

On-Vehicle Service

Required Service Materials

Special Tools

Section 6H Charging System

Battery

Generator General Description

Specifications

Section 8 Body Electrical System

General Description

Diagnosis

On-Vehicle Service

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