TABLE OF CONTENTS -

- -

1 SERVICE DATA - - - -

[Wtuar SHOO

FUEL PUMP AND FILTER

I ENGINE COD^^ SYSTEM -

1 CAR HEATER
IGNITION SYSTEM
--

STARTER MOTOR
-- - - -

I CHARGING SYSTEM
-

I GEAR SHIFTING CONTROL

1 SUSPENSION -

I STEERING SYSTEM
--
 1. GENERAL

1-1 . Exterior View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

.
12. . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
.
13. . Locations of Engine Numbel and Body Number . . . . . . . . . . . . . . . . . . . . . .1-7
14. . Standard Shop Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
15. . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

6.1 . Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

.
1-1. Exterior View

( The photo shows standard specification. I

1-2. Specifications

HATCH

DIMENSION
Standard spark plug NGK BP5ES
1-3. Locations of Engine Number and Body Number
The engine number is punched on the skirt part The body number is punched on the body in the
of the cylinder block under the carburetor. engine room as shown below.

~ i g .I - 1 . Location o f Engine No. Fig. 1-2 Location o f Body No.

1-4. Standard Shop Practices 4. To work on the front or rear end raised by
jacking, be sure to place the safety stand
1. Protect the painted surfaces of the body, and under the front suspension frame or rear axle
avoid staining or tearing the seats. When to support it in stable condition.
working on the fenders and seats, be sure
to cover them up with sheets.
2. Disconnect the negative terminal connection
of the battery when working on any electri-
cal part or component. This is necessary for
avoiding electrical shocks and short-circuit-
ing, and is very simple t o accomplish: merely
loosen the wing nut on the negative terminal
and separate the cable from the terminal post.
3. I n raising the front or rear end off the floor
by jacking, be sure to put the jack up against
the center portion of the rear axle housing
or front suspension frame.
Fig. 1-5

Fig. 1-3
Fig. 1-6

5. Have wheel chocks for ready use in the shop.

Chock the wheels securely when raising one
end of the m'achine.
6. Orderliness is a key to successful overhauling.
Trays, pans and shelves are needed t o set aside
the disassembled parts in groups or sets in
order to avoid confusion and misplacement.
This is particularly important for engine over-
hauling.
7. Have on hand the liquid packing - SUZUKl
Fig. 1-4 BOND No. 4 (99000-31030) - for ready use.
This packing dope is an essential item assures
leak-free (water and oil) workmanship.
 8. 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 speci-
fied: be sure t o use torque wrenches on those
bolts.
9. I t is advisable t o discard and scrap gaskets and
"0" rings removed in disassembly. Use new
ones in reassembly, and try not to economize
gaskets and "0" rings.
10. Use of Genuine SUZUKl parts is imperative.
Use of imitation parts is a big gamble on
safety and performance. Use Genuine Fig. 1-7 Engine cylinder numbers
SUZUKl parts and live up to the trust your
customer places on you.
11. Special tools save time and ensure good work-
manship: 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 disassem-
bly and reassembly steps.
12. Refer t o 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. 1-7. Counting from the
crankshaft pulley side, the cylinders are
referred to as No. 1, No. 2 and No. 3
cylinders.
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 this Model:

(A) Valve guide & valve stem seal

handle
(6)Valve stem seal installer attach-
09916-14510 ment 099 16-44510
Valve lifter (Cl Valve guide installer attachment Valve guide remover

Valve guide reamer

( A ) 7 mm dia
(B) 12.0 rnm dia 09916-84510 09916-97820
(C) Handle Forceps Flywheel stopper
7.

09915-47310 09916-77310 09915-77310

Oil filter wrench Piston ring compressor Oil pressure gauge
10. 11. 12.

099 15-64510 09915-67310 09930-40113

Compression gauge Vacuum gauge Camshaft lock holder
 09900-09002
Shock driver set
09900-25002
Pocket tester 1 09900-27003
Ionition tirninq tester
16. 17.

09900-28106 09915-27810 09913-61110

Electro tester Hexagon socket (10 mm) Bearing puller
19. 20.

09900-06108 09900-06107
Snap ring pliers (closing type) Snap ring pliers (opening typc Tie-rod end puller
22. 23.

09913-80112 09913-75810 09913-75820

Bearing installer Bearing installer Steering pinion bearing installer
25. 26.

09913-75830 09922-55121 09922-85811

Steering pinion bush installer Drive shaft installer Spring pin remover
 09923-37810 09942-45810 09943-25810
Clutch center guide Steering plug setting tool Coil spring setting tool
31. 32 33.
'"9
~,

G,,
\, -Y'

09913-17310 09943-17910 09942-15510

Carburetor adjuster Front wheel hub remover Sliding hammer

09900-27301
Timing light
1-6. Required Materials
The materials listed below are needed for maintenance work on thisvehicle, and should be kept on hand
for ready use. In addition, such standard materials as cleaning fluids, lubricants, etc., should also be
available. Methods and time of use are discussed in the text of this manual on later pages.

Ref. Material
No.
-

Additive to engine cooling for im-

GOLDEN CRUISER 1200 proving cooling efficiency and for
"Anti-freeze and Summer Coolant" protection of wet walls against
(99000-24120) rusting.

0 For locations indicated in the sec-

tion dealing with the starter motor.
e Clutch release bearing retainer.
0 Clutch release shaft bushing.
0 Transmission oil seal.
0 Differential oil seal.
0 Steering column.
0 Gear shifting control lever bushing
& seat.
e Door window regulator.

SUZUKl GREASE SUPER H

v-..223
<ye--
Special grease intended for use on
constant velocity joint.
(Drive shaft joint)

For top and bottom mating faces

SUZUKl BOND (No. 4) of transmission case.
4. e For other locations specifically
(99000-31030)
.,*-.*fit eorJD indicated in the text of this
SU~~,-- manual.
 e Timing belt inside cover bolt
5. THREAD-LOCK CEMENT
(99000-32040)
0 Back window hinge screws

e Steering gear case

SUZUKl SUPER GREASE E Steering rack
6.
(99000-25050) 0 Steering pinion bush
Steering rack boot
--

0 Rear axle spindle cap

7. WHEEL BEARING GREASE e Front wheel bearing
e Rear wheel bearing

e Transmission case
1 GEAR OIL S A E # 9 0 2.0 ltr. (4.213.5 USIlrnp. pt.)
Transmission gear and bearing,

For engine oil pan: 2.5 litres

(5.314.4 USIlmp. pt.) for peri-
odical oil change but 3.0 litres
(6.315.3 USIlmp. pt.) for re-
4-STROKE ENGINE OIL filling a t the time of engine over-
hauling.
e Crank journal bearings and thrust
plate.
e Connecting-rod big-end and small-
Proper oil viscosity chart end bearings.
@ Camshaft journals and thrust plate.
0 Rocker shafts.
SAE Oil pump gears.
I 2OW-40,2OW-50 a
0
Pistons and piston rings.
Engine oil seals.
Valve stems.
0 Accelerator, choke and clutch
cables.
Parking brake cable.
@ Accelerator, brake and clutch
pedals.
Temperature e Door locks and hinges.
Distributor gear.
lo' SEALING COMPOUND 366E
(99000-31090)
&p? A? e Brake backing plate

11. THREAD LOCK CEMENT SUPER 1342 e Timing belt tensioner bolt
(99000-32050)

12. BRAKE FLUID "DOT 3, DOT 4" or SAE J1703 o Brake fluid reservoir tank
I