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    23 views18 pages

    Chapter 1 PDF

    Uploaded by

    Oriel Roberto Robles Vicencio

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 18
    TABLE OF CONTENTS GENERAL TROUBLE SHOOTING ENGINE CARBURETOR AIR CLEANER, FUEL PUMP AND FILTER ENGINE COOLING SYSTEM CAR HEATER IGNITION SYSTEM STARTER MOTOR CHARGING SYSTEM CLUTCH GEAR SHIFTING CONTROL TRANSMISSION PROPELLER SHAFT DIFFERENTIAL SUSPENSION STEERING SYSTEM BRAKES BODY ELECTRICAL EQUIPMENT SERVICE DATA AND MAINTENANCE SCHEDULES OTHERS N 3 = | a aR = Se 1, GENERAL Exterior View Specifications Locations of Engine Number and Body Number Standard Shop Practices ... Special Tools Required Materials 1-1. Exterior View sT90 Fig. 1-1 ST90K Fig. 1-2 1-2. Specifications Models Item S90, ST90K sT90v DIMENSIONS Overall length 3,195 mm (1258 in) | Overall width 1,395 mm ( 64.9 in) —— Overall height 1,660 mm ( 65.4 in) —— Wheelbase 1,840 mm (72.4 in) —— Tread: Front 1,215 mm ( 47.8 in) Rear 1,200 mm { 47.2 in} Load deck size: Length 1,940 mm ( 76.4 in) 1,660 mm ( 65.4 in) *1_*4 1,845 mm ( 72.6 in) *1*3 940 mm ( 37.0 in) *2 *4 Width 1,320 mm { 52.0 in) 1,250 mm ( 49.2 in) Height 290 mm ( 17.4 in) 1,150 mm ( 45.3 in) | Ground Clearance 170 mm (__6.7 in) WEIGHT ‘Curb weight 645 ka (1,422 Ibs) *4 705 kg (1,554 Ibs) “4 650 kg (1,433 Ibs) *3 700 kg (1,543 Ibs) *3 Weight distribution: Front 380 kg (838 Ibs) 390 kg ("860 Ibs) *4 385 kg (_ 849 Ibs) *3 Rear 265 kg (584 Ibs) "4 315 kg (694 Ibs) 270 kg (_ 595 Ibs) *3 Gross vehicle weight 1,350 kg (2,976 Ibs) 1,350 kg (2,976 lbs) ‘Seating capacity 2 persons 2 or 4 persons 4 2 persons #3 ‘Maximum loading capacity 600 kg (1,323 Ibs) 550 kg (1,212 lbs) *1*3 *4 420 kg (_925 Ibs) *2 "4 ENGI Type Four stroke cycle, water-cooled, OHC —_— Number of cylinders 4 ———— Lubrication system ‘Wet sump. —— Bore 62.0 mm (2.441 in) Stroke 66.0 mm (2.598 in) Piston displacement 797 cm? (797 cc, 48.6 cu.in) Compression ratio 87:1 ———— Carburetor MIKUNI 30 PHD, single — Air cleaner Dry type — Passengers *2.. 4-Passengers *: .. For Australian market For other markets Models Item: ST90, ST9OK ‘ST9OV ELECTRICAL Ignition timing 14° B.T.D.C. at 900 r/min (rpm) baer eee Standard spark plug NGK BPSES or NIPPON DENSO WI1GEX-U erent Starter Magnetic shift type —— Generator = Alternator ————— Battery _12V, 126 KC (35AH)/20 hours — Headlight 12V, 50/40 W nena Turn signal light 12V, 21W. — Clearance light 12V, SW )- JEEEEERESEEERS Parking light “T2v, 5W ——— Tail/Brake light 12V, 5/21W — Side turn signal light 12V, 6W saree ee Licence plate light 12V, 10W —_ Back up light 12V, 10W Sn Room light 12V, 5W et Meter pilot lights 12V, 3.4W puSPuSAESIEEEDy ‘Main fuse 30A Sees Fuse box 20A, 154, 15A, 154 ————— POWER TRANSMISSION Clutch type Dry, single disc ——— Transmission type \4-forward all synchromesh, 1 reverse | Final reduction ratio 5.125 Gear ratios: Low 3.428 2nd) 2.108 ‘3rd 1.379 | Top 1.000 reverse 3.600 WHEEL AND SUSPENSION| oi Tire size: Front and rear 4.50-12.8PR 4 Front 180 kPa (1.8 kg/cm?, 26 psi) —when loading under 200 kg (440 Ibs)_*4 240 kPa (2.4 kg/cm? , 34 psi) —when loading over 200 kg (440 Ibs)_*4 Tire pressure Rear 180 kPa (1.8 kg/cm?, 26 psi) —when loading under 200 kg (440 Ibs)_"4 ‘375 KPa (3.75 kg/cm? , 53 psi) —when loading over 200 kg (440 Ibs) _*4 THN Ul =10- Models ST90, ST9OK ST90V + Item WHEEL AND SUSPENSION Tire size: Front and rear 145R12-6PR “3 Front 160 kPa (1.6 kg/cm? , 23 psi) —when loading under 200 kg (440 Ibs) *3 180 kPa (1.8 kg/cm? , 26 psi) —when | loading over 200 kg (440 Ibs) *3_| Tire pressure Rear 160 kPa (1.6 kg/cm? ,, 23 psi) —when loading under 200 kg (440 Ibs) *3 ‘280 kPa (2,8 kg/em? , 40 psi) when loading over 200 kg (440 Ibs) *3. Suspension type, Front Strut ——— Rear Leaf spring —— ‘STEERING Turning radius 4.1 m (13.45 ft) ——— Steering gear box Ball-and-nut type —— Toei | Weniele with 4.50-12-8°R 11~ 15 mm (0.43 ~ 0.59 in.) — Vehicle with 145R12-6PR 3~ 6 mm (0.12 ~ 0.24 in.) — Camber angle 1°30" Sa Caster angle 2 30° — Trail 11mm (0.43 in) eee King pin angle 12° 30" =—— BRAKE SYSTEM Type 4-wheel, hydraulic —_— Wheel brake, Front Two-leading — Rear Leading and trailing Seeaeoeeeeees Parking brake Mechanical, 2-rear wheels —— CAPACITIES Cooling solution 4.5 8 (9.5/7.9 US/Imp pt) See Fuel tank 36.08 (9.5/7.9 US/Imp gal) ———— Engine oil 3.0 £ (6.3/5.3 US/Imp pt) Beer! Transmission oi! 1.02 (2.1/1.8 US/Imp pt} — Differential gear box oil 1.08 (2.1/1.8 US/Imp pt) -u- 1-3. Locations of Engine Number and Body Number The engine number is punched on the right: hand skirt part of the cylinder block under the carburetor. Fig, 1-4 Location of Engine No, The body number is punched on the upper surface of the right-hand tire housing located under the seat. rs Fig. 1-5 Location of Body Wo. For European Market The body number is punched on the wall under the right side seat. Fig. 1-5-1 Location of Body No. -12- Standard Shop Practices 1, Protect the painted surfaces of the body, and avoid staining or tearing the seats, When working on the fenders and seats, be sure to cover them up with sheets. 2. Disconnect the negative terminel connection of the battery when working on any electri- cal part or component. Thisis necessary for avoiding electrical shocks and short-circuit- ing, and is very simple to accomplish: merely loosen the wing nut on the negative terminal and separate the cable from the terminal post. 3. In raising the front or rear end off the floor by jacking, be sure to put the jack up against the center portion of the axle ho Fig. 1-7 4. To work on the front or rear end raised by jacking, be sure to place the safety stand under the axle to support it in stable condi- tion, Hise Fig. 1-8 Fig. 1-9 5. Have wheel chocks for ready use in the shop. ‘Chock the wheels securely when raising one end of the machine, Orderliness is 2 key to successful overhaul- \g. Trays, pans and shelves are needed to set aside the disassembled parts in groups or sets in order to avoid confusion and misplace- ment. This is particularly important for engine overhauling, Have on hand the tiquid packing~SUZUKI BOND No. 4 (99000-31030) — for ready Use. This packing dope is an essential item assures leak-free (water and oil) workman- ship. Each bolt must be put back to where it was taken from or for which it is intended. Do not depend on your hunch in tightening the bolts for which tightening torque values are specified: be sure to use torque wrenches on those bolts. 9, It is advisable to discard and scrap gaskets 10. Use of Genuine SUZUKI parts u. and “0” rings removed in disassembly. Use new ones in reassembly, and try not to economize gaskets and “0” rings, imperative. Use of imitation parts is a big gamble on safety and performance. Use Genuine SUZUKI parts and live up to the trust your ‘customer places on you. Special tools save time and ensure good workmanship: They are available from SUZUKI, Use them where their use is specified. Moreover, your own safety is assured by the use of special tools in many of the disassembly and reassembly steps. 12, Refer to the contents of this MANUAL as often as practical, and do each job right as prescribed. NOTE: The engine cylinders are identified by numbers. See Fig, 1-10. Counting from the front end, the cylinders are referred to as No. 1, No. 2, No. 3 and No. 4 cylinders. Fig, 1-10 Engine cylinder numbers -14— 1-5. Special Tools ‘Special tools assure three things: 1) improved workmanship; 2) speedy execution of jobs for which they are meant; and 3) protection of parts and components against damage. Here are the special tools pre- scribed for the Model ST90, ST9OK and ST9OV: 1 2 TT wages 8 , (A) Valve guide & valve stem seat handle 09016-1510 (6) Vat stem sal intatier attach iaore anal Valve lifter (C) Valve guide installer attachment Valve guide remover 4 coosaseeze © 5. 6. ‘pe16- 34540 = B o901637310 ‘Valve guide reamer (A) 7 mm di (B) 12.0 mm dia, 09916-84510 09916-97910 (C) Handle Forceps Flywheel stopper 7. 8. 9. 09915-47310 09916-77310 09915-77310 Oil filter wrench Piston ring compressor Oil pressure gauge 10. 11. 12. 09915-64510 09915-67310 (09930-40113 Compression gauge Vacuum gauge Camshatt lock holder —15- 13. 14, 6. 09900-09002 09900-26002 09900-27003 Shock driver set ____ Pocket tester Ignition timing tester 16. 17. 16 J A~N SY 09900-28106 09911-70120 09913-60910 Electro tester Hexagon wrench 6 mm. Bearing puller 19. 20. 21 — = ay \ > Z Pd 09913-85210 09900-06108 09900-06107 Differential rear outer Snap ring pliers (closing type) Snap ring pliers (opening type) race installer 22. 23 24, > (09913-76010 09940-53111 09913-80111 Differential front outer Differential side bearing ing installer race installer installer 26. 27. y 09913-85230 Differential side bearing 09922-55131 09922-85811 remover jig Bearing installer Spring pin remover —16— 28. ~ “oe 09922-75220 09923-57910 Differential pre-road 09923-36310 Differential side bearing checking tool Clutch center guide adjuster turner 32.

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