21. OTHERSNOTICE Given below are the details of modifications of the engine valve spring, final gear ratio, combination switch, and wiring diagram. [These modifications have been carried out since May 1981 production, that is, on and after the following body numbers, ‘These changes have been carried out on and after the following body numbers For European Market _ For the Other Market Body No. ST9OK . . . [/SAOST0K00102001> Body No. ST90-114001 ST90V ... SJSAOST90V00107001= 8790-72001 21-1. Engine Valve Spring Wire diameter “D" of the engine valve spring was modified from 4.2mm (0.17 in) to 4,0mm (0.16 in). In nen ecuence of this, service data for valve spring in each service manual were modified as follows, Bur the ew and old engine valve springs are interchangeable, — ow NEW [tem ‘Standard | Lime | tem [Standard Limit] jVaive | ] Valve | termes | iarroin) | (neaor ny reste! Giaasam | cuaseo'ny ith 8779 in, 8307 in, tera ‘ in, in ale 26-30 kg for | 24 kg for > va 23.6 ~ 27.6 kg for | 22.0 kg for e 40 mm 40 mm ales 40 mm 40 mm Preloag | (87.3-66.1 by | (52.9 Ib/ | precy | (520~60.81b/ | (48.5 o/ ee 1.57 in.) 1.57 in) [pried | ny e7in) 1.87 in.) 21-2. Differential The numbers of the bevel gear and pinion gear were changed as follows, ITEM l MODEL oo | new Teeth number of bevel gear | S90 series aa 36 Teeth number of pinion gear ‘ST90 series | 8 7 Final reduction ratio ST90 series 6125 | 6.142 [interchangeability) The old and new bevel years and pinion gears are interchangeable if replaced ‘together in a set. ~262~21-3. Combination Switch ‘A multicontrol type switch as shown below was employed instead of the existing combination switch. The old and new switches are not interchangeable. This multicontrol type switch has been installed in the model of the West German specifications from its initial production, OLD NEW Turn signal & dimmer and lighting switch lever ‘Turn signal & dimmer switeh lever Hazard warning switeh kniob Wiper & Washer ==21-4. Wiring Diagram (For European Market except Germany) ST90/80K(For European Market except Germany) sT90visraov) (For German Market) ‘ST80/90K/90V ——— NOTE: This diagram is applicable from initial production. | oc sascesnroy Bifieam | (sta0v) fa A aaa Wire color 8 ack y Yellow Bho... ue Bar. Black with Wmite tracer er Brown ay ck with Yellow tracer s Green Blew > Blue wen Wite racer R Rea IR > Green with Rod acer We wate Gow > Green wth Wit racer — 268 —(For The Other Market) ST90/90K(For The Other Market)21-5. Installation Procedure of Engine Valve Stem Oil Seal Indiscriminate or incorrect installation of the valve stem oil seal causes increase in engine oil consumption. Therefore, the following instruc- tions must be observed very carefully. 1, Don't reuse the oil seal once removed. It must be replaced with a new one. 2. Before installing the oil seal, check to ensure that the special tool and the valve guide are free from any dust and soak the oil seal in the oil. 3. Fit the oil seal to the special tools @ and @, and push the special tool into the valve guide with hand until the oil seal is installed (when the hand feels installation). CAUTION: Never hit the oil seal or special tool with a hammer or anything of that sort while installing the oil seal. GD: Valve stem seal handle (Part No. 09916-57320) @ : Valve stem seal installer attachment (Part No. 09914-77310) 21-6. Replacement Procedure of Rear Wheel Bearing Should the rear wheel bearing need to be replaced, remove the rear shaft first refering to the differential removal section in this manual. And then remove the bearing from the shaft for replacement. a “Sy z= Oil seal protector Oilseal wat | Retainer ring REPLACEMENT NOTE: The retainer ring is very tightly fitted on the axle shaft so as to prevent the rear axle shaft from coming out of the axle housing while driving, This is why @ grinder is needed for its removal.« Inorder to remove the retainer ring from the shaft, grind with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin, CAUTION: Be careful not to go so far as to grind the shat with 3 grinder axle shaft Rear wheel bearing retainer ring Grind with a grinder Break with a chisel the thin ground retainer ring, and it can be removed. Remove the beat an hydraulic press. ~275— 4, Press in a new bearing and retainer ring in order by using an oil hydraulic press, NOTE: At this time, protect the outer surface of the retainer ring from any damage. A damage on the outer surface of the retainer ring will cause an oil seal lip wear which eventually allows differential oil to leak on the brake shoe When pressing the retainer ring, pressure. apply 3 to 5 ton After making sure that the ring contacts the bearing, clean the ring surrounding and apply sufficient amount of wheel bearing grease to the bearing. 5. Fit the oil seal onto the shaft and install the shaft in the body in the reverse order of its removal. 6. Make absolutely sure to replenish differential il after installation,21-7. Starter Motor To improve the engine start, a pa tion was carried out on the starter. Effective body No,: For European Market modifica For the Other Market Essaosteoxoo102190%~ — $T90-115977 ~ BusaosTaovooiogss7Z~ — sT90-736413 ~ OLD | nition Ignition coil ‘itch = Battery Starter motor (For W. Germany end Switzerana) 8/505 ST] Reenter |, | tonition tonition of Pexeail switch To airibater ame (1 Starter motor Ignition coil To distributor ( Battery Starter motor —276— By this modification, the electric current flow at the time of engine start (when the main switch is turned to the start position) was changed. With the new starter motor, it flows directly from the battery to the ignition coil through the contact point “A” in the magnet switch of the starter motor, while it passed through the resistor of the ignition coil before modific As a result, the voltage drop of the ignition coil is avoided and the engine start is made even easier. 21-8. Differential Carrier Modifications were carried out on the differen- tial carrier and its related parts according to the applicability given below. With the new differential carrier, the gasket is isused and sealant is applied instead. Also, the differential carrier and the carrier bolt were modified as shown below. Effective body No.: For European Market __—_~For the Other Market ssaosrooKoot21e9%~ s90-115802~ FsaosTeovooies42%~ st90735871 ~ ‘Axle housing carrier bolt S= (It was changed from stud bolt to hexagon bolt) e 9mm +9.5mm (0.35 in, > 0.97 in.) Differontial carrier (Its mating surface with the axle housing was made 0.5 mm (0.02 in.) thicker)SERVICING If the modified differential carrier ass'y has been removed from the axle housing, make sure to clean their mating surfaces before reinstallation. (Check to ensure that they are free from old sealant or oil.) Apply SUZUKI BOND No. 4 (Part No. 99000- 31030) to the differential carrier and fit it to the axle housing. ‘Apply SUZUKI BOND No. 4 Differential Carrier LL -7-woo'ubelpseo -78-NEW MODEL TECHNICAL BULLETIN SUZUK'! TOPE T0) ET) LE) = ‘ST90K ST90V In order to further improve marketability and performance of the above models, modifications will be ‘carried out starting with ’83 January production (March production for European specifications). They are on interior and exterior designs and some parts of the suspension, steering, brake, body, electrical and heater. This bulletin is to provide descriptions of the modifications carried out on significant parts, the changeability and precautions to be taken in servicing, For the new parts supply and parts numbers, refer to Parts Catalogue issued by Export Parts Section. ‘These modifications wil be carried out on and after the following body numbers. For European Market For the Other Market Body No. ¥JSAOST90K00105001¥ Body No, ST90-125001 ¥ JSAOST9OVO0125001 = ‘ST90-755001 MODIFICATION INTERCHANGE: Pants MODIFICATION ERCHAN T Front supenaion | Damping free at the tima of expansion increased. oo =" NeW srr ‘strut support | ®Support bracket, rubber and rebound stopper separsted (used to | OLD =f NEW teow uni 3 5 | erontsupenion | «Tension od egthened by 1 mm (0030 n} and psn water | anew sion rod, it & | tomonroa scar ted wrt lan “ washer, is usable for ‘Reeth btore te rmodtioton{onetouch ft) type INTERCHANGE PARTS ooircarion RCIA Steering whee! | Steering whee reshaped and horn buttons mounted on spoke, | OLD =¥7 NEW > a, Z ead | suering att | steering sata colin lengthened and swing wheel rated | OLD SH NEW § | Sterngcournn | “by tom (030 n by hanpng penton of clue naeton B Race” | Ree w pce rate x 10mm (020 sot wee ing shen _ 7 | ‘rake raver | ©Cap materi changed torn ou =gNew wy | evince ere 2 | cine | rate ive No.1, | Brake pin banded shave changed and protect adéed toa pert | OLD 7 NEW Note crepe Trion cot | To id misconeation, yan Gra tne connected te | OLD 3 NEW inion ca ak iho he hr tia Pa IR oa} I, 3 seostane | nd ht rim espe oto Zit new 5 Licence light ‘@Material changed to resin ‘oLo St" New nd wetage changed trom se ‘ou tos ta tor European petting | sa turnsanat_ | sinstatation changed rom ovo 3 new | fore sored pe toni — 280 —ELECTRICAL INTERCHANGE PARTS: ‘MODIFICATION yey Starting motor | ® Coupler coupled with main fuse reshaped. LTT NEW cable Main foe ‘@cchanged to fusible link type. OLo=eTNEW Fuse box ‘eChanged to blade typ. OLOTZTNEW Windshield wiper | eWiper bracket reaped in accordance with reshaped front panel | OLOZ” NEW Wiring hacrass | Fuse related circuits modified. OLDS 57 NEW (Now wiring dia: {tam attached at ‘he end oF this bulletin) “The mew fuse box ie wired a follows For General and European Market except West Germany Apt ea ma — sie ie, cote» —v— a For west om $$ 1] oscar lara Seve aa 4 al seer ien inten ‘Germany Market seatINTERCHANGE. PARTS MODIFICATION rece Front grille ‘Design mosiiea. OLD e"NeEw Front bumper | ehtaterial changed to resin, ovo =StNEw Front combination lights installed § mm (0.20) higher and distance between them made 25 mm (0.98 in} argue Hom mounting position moved 40 mm (157 in) toward the conte & | Front panet ‘Bartally reshaped and head light mounting postion raised by | OLD HE“ NEW 8 30mm (1-181), Front Hor panel_| ¢Strut support mounting holes postion chenged. ovo New Yao 112 1" 7 Set opr Ke ~ 120° S28 Instrument panel | ¢Shape and design modified 0.0 =f New Car heater ‘¢Resheped so 2s to take in more sir for better heater performance, | OLD "NEW CAR HEATER ¢¥later vave installed at the top end of heater inlet hose. Water valve can be operated with the lever on instrument pana, ‘sHeater control lever operation changed from right and left type 10 up and down type. ater vahe (Hot > coo) ote lee Heater itt | fom — 282 —PARTS INTERCHANGE- MODIFICATION ABILITY FUEL. Charcoal canister (For Australian ‘Market) Check valve {For Australian Market) ‘*Carcoal canister ie added in the fuel evaporative emission control system and the piping is as shown below. | Lasiapor = ‘aowrntor £G [ors Fea sept we ‘echeck vole i added tothe fue return pipe. v7SERVICING Front suspension strut When installing @ new strut (whose strut support is separate type), note the following as well as what is aiven as Important Steps in Installation in Group 16 of ST90/90K/90V Service Manual Support rabber cde tng un ” Charcoal canister (For Australian Market) When inspecting the charcoal canister, carry ‘out in accordance with the following pro- cedure. 1) Remove the charcoal canister. 2) When air is blown into pipe A, there should bbe no restriction of current through pipes B and C. A From tu! san '3) When air is blown into pipe 8, air should not ass through either pipe A or C. scien Ore 4) When air is blown into pipe C with pipe B closed by finger, air should be pass through pipe A, '5) When air is blown into pipe C with pipe A closed by finger, air should be pass through pipe 8 6) If operation differs from above procedure, ‘the charcoal canister must be replaced. 7) The Canister is cleaned by blowing 40 psi (3 kg/em*) of air into pipe A while sealing pipe B with a finger ~284—woo'ubelpied‘ST90/90K For General Market‘ST9OV For General Market 288 —'ST90/90K For European Market except West-Germany -290—ST9OV For European Market except West-GermanyA ee dese & pie : aia L a 4 x Scand sue 7 In oe L, Eee... (le aii laa 1 Dstt aymmnmni E =) vw ¢ StS F a { = EQ er es ST psn = 5 ae Hinapenzen = i eee “nasa 7a | eer zis) ; | La) Te ‘cae * fanaa | Lesa Jo pe t i fl... euckwth sue wac W/o... tein ren waa aes Sees Bert hes See eacae : SS Rossin sewer iy. Rasen ne ie RAY 2 Red win Yalow tracer Wo > whieh Black torST9OV For West-Germany Market — 294i ‘antennal en al! WG... White with Groen tocar R08 War 2 write wen Rag acer Bre ve se RIG Via ‘vecee am vic iow ath Grevn toe Be | death Yolo acer Y/R || Yalow wth Rea tacer (hls rite we Blac acer YAW Yalow wth Wie ae =295— z Ls _ yp ern 9) eeeSUZUKI MOTOR CO.,LTD. Technical Department Automobile Service Division 99502-79200-01E = 296 Jan., 1983 Printed in Jopan