Suzuki LJ80 - Service Manual

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Table of Contents2
General: Contents3
Body and Chassis of Suzuki LJ80 and LJ80V4
LJ80 and LJ80V Chassis with Engine5
Outline Dimensions LJ807
Outline Dimensions LJ80V8
Specifications9
Locations of Body Number and Engine Number12
Standard Shop Practices13
Engine Cylinder Numbers14
Special Tools15
Required Materials19
Troubleshooting: Contents21
Engine Troubleshooting22
Poor Starting22
Not Enough Power23
Sudden Drop of Speed in High Speed Cruise24
Engine Not Responding Quickly to Pedal Control in Picking up Speed24
Erratic Idling25
Abnormal Detonation25
Engine Overheating26
Abnormal Engine Noise26
High Fuel Consumption27
Excessive Engine Oil Consumption27
Carburetor Troubleshooting28
Exhaust and Muffler Troubleshooting28
Clutch Troubleshooting28
Transmission Troubleshooting29
Differentials Troubleshooting30
Propeller Shafts Troubleshooting31
Brakes Troubleshooting31
Front Suspension and Steering System Troubleshooting32
Starting Motor Troubleshooting33
Alternator Troubleshooting34
Wiper Motor Troubleshooting35
Fuel Meter Troubleshooting36
Turn Signal Lights Troubleshooting36
Speedometer Troubleshooting37
Water Temperature Meter Troubleshooting37
Oil Pressure Warning Light Troubleshooting37
Charge Warning Light Troubleshooting38
Horn Troubleshooting38
Engine: Contents39
Engine: Description40
Engine Features41
Blowby Gas Recycling System42
Engine Services Not Requiring Engine Removal43
Dismounting the Engine44
Engine Disassembly45
Engine Maintenance Service53
Cylinder Head53
Rocker Arm Shaft and Rocker Arms54
Valve Guides55
Valves56
Valve Seats57
Valve Springs59
Engine Reassembly60
Tightening Torque Data60
Oil Seal Housing61
Oil Pump62
Piston and Piston Rings62
Connecting Rods63
Oil Pump Strainer64
Oil Pan64
Flywheel, Cylinder Head65
Camshaft66
Rocker Arm Shafts67
Water Inlet Pipe68
Crankshaft Timing Belt Guide68
Cylinder Head Front Side Case68
Camshaft Timing Belt Pulley69
Timing Belt (Valve Timing Adjustment)69
Valve Clearance Adjustment70
Distributor, Distributor Gear Case71
Alternator71
Clutch72
Engine Inspection and Adjustments73
Timing Belt74
Measuring/Adjusting Valve Clearance74
Oil Pimp Discharge Pressure Measurement75
Vacuum Measurement75
Compression Pressure Measurement75
Engine Oil, Oil Filter, Coolant76
Exhaust Line and Muffler76
Oil Filler Cap76
Crankcase Ventilation Hose76
Engine Lubrication77
Oil Pump Disassembly, Inspection78
Oil Pump Reassembly79
Checking Oil Pressure80
Oil Filter Servicing80
Oil Pump Strainer Servicing80
Engine Oil Servicing81
Oil Level Gauge81
Carburetor: Contents82
Carburetor Description, Specifications83
Carburetor Circuit Diagram84
Carburetor Operation85
Float Chamber85
Slow/High Speed Mixture85
Acceleration Power System85
Inspecting and Adjusting86
Jets86
Choke Valve86
Needle Valve86
Accelerator and Choke Cables87
Fuel Tank Cap87
Fuel Level Adjustment87
Fuel Hose87
Idle Speed and Idle Mixture Adjustment88
Air Cleaner, Fuel Pump and Fuel Filter: Contents90
Air Cleaner Description91
Air Cleaner Element Inspection and Servicing91
Use of the Selector Level92
Fuel Pump93
Fuel Filter Servicing and Installation94
Engine Cooling System: Contents96
Engine Cooling System: Description97
Cooling Water Circuit97
Engine Cooling System Removal98
Coolant Draining98
Radiator Removal98
Removal of Cooling Water Pipers, Cooling Fan Removal98
Water Pump Removal99
Water Reservoir Tank99
Thermostat99
Radiator Filler Cap99
Requirements on Coolant100
Water Pump100
Golden Cruiser 1200 "Anti-Freeze and Summer Coolant" - Its Effects and Use101
Water Temperature Gauge102
Anti-Freeze Proportioning Chart102
Cooling System Services103
Thermostat, Fan Belt103
Coolant Level104
Radiator104
Water Hoses104
Important Re-Installing Steps105
Filling up the Cooling System105
Car Heater: Contents106
Car Heater: Description107
Car Heater: Electrical Circuit107
Heater Services108
Fan Resistor108
Fan Switch108
Ignition System: Contents110
Ignition System: Description111
Distributor112
Ignition Coil113
Spark Plugs113
Timing Advancer113
Maintenance Services114
Distributor Cap, Spark Plugs114
Distributor Driven Gear114
Contact Point Faces114
Checking the Primary Circuit for Fault115
Ignition Coil, Condenser115
Important Reminders for Reassembly and Installation: Distributor116
Ignition Timing Specifications117
Ignition Timing Checking Methods117
Important Reminders for Reassembly and Installation: High Tension Cords117
Replacement of Distributor Driven Gear119
Starter Motor: Contents120
Starter Motor: Description, Specification121
Cranking Action122
Starting up the Motor122
Pinion Meshing with the Ring Gear122
Starter Motor Removal123
Engine Cranking123
Terminating Cranking Operation123
Starter Motor Disassembly124
Checking the Field Coils125
Servicing the Communicator125
Checking the Armature125
Testing the Magnetic Switch126
Servicing the Brush Holders126
Servicing the Brushes126
Important Reminders for Starter Motor Reassembly127
Charging System: Contents128
Charging System: Description129
Charging Operation130
Alternator Description132
Alternator Data and Specification133
Alternator Removal/Disassembly133
Testing the Rotor for Open Circuit134
Testing the Rotor for Grounding134
Stator, Brushes, Rectifier - Servicing135
Alternator Load Performance135
Alternator Regulator: Specifications, Maintenance Services136
Guide on Regulator Diagnosis138
Main Fuse139
Battery Specifications139
Care of the Battery140
Clutch: Contents142
Clutch: Description143
Clutch: Removal144
Clutch Maintenance Services144
Clutch Disc Facing Surface Condition144
Clutch Facing Wear144
Backlash in Disc Serration Fit145
Release Bearing145
Inspect Shaft Bearing and Oil Seal145
Clutch Cover145
Clutch Disc and Clutch Cover Installation146
Clutch Pedal Height146
Clutch Pedal Play146
Input Shaft Bearing147
Clutch Release Bearing Retainer147
Clutch Release Arm147
Gearshifting Control: Contents148
Gearshifting Control: Description149
Gearshifting Control: Removal150
Gearshift Lever Adjustment150
Guide Plate Inspection150
Gearshifting Control Installation151
Transmission: Contents152
Transmission: Description153
Flow of Drive through Transmission154
Transmission Gear Ratio156
Transmission Dismounting, Disassembly156
Removing the Countershaft157
Removing the Main Shaft and Input Shaft157
Removing the Shifter Fork Shaft and Forks158
Transmission: Maintenance Services159
Reverse Gears and Idle Gear159
Countershaft and Its Bearings159
Input Shaft160
Combination of Gear and Synchronizer Ring160
Chamfered Tooth Ends of Ring and Sleeve160
Synchronizer Rings161
Transmission: Important Step in Installation162
Tightening Torque162
Input Shaft and Main Shaft162
Extension Case Bush162
Shifter Forks and Shafts163
Reverse Gears and Idle Gear, Extension Case Oil Seal164
Input Shaft and Main Shaft Installation, Putting Together Upper and Lower Cases164
Transmission Oil165
Transfer Gear Box: Contents166
Transfer Gear Box: Description167
Selective Flows of Transfer Drive168
2-Wheel Drive168
4-Wheel Drive High168
Gear Ratio Data169
Transfer Gear Box Removal169
4-Wheel Drive Low169
Transfer Gear Box Disassembly170
Universal Joint Yoke Flanges170
Center Brake170
Speedometer Driven Gear, Transfer Gear Control Lever170
Upper Transfer Cover171
Transfer Front Case, Countershaft171
Shifter Fork Shafts172
Transfer Gear Box Maintenance Services173
Gear Teeth173
Output Rear Shaft173
Locating Spring173
Transfer Gear Box Important Steps in Installation174
Parking Brake174
Output Rear Shaft, Shifter Fork Shafts and Forks175
Locating Spring and Balls for Shifter Fork Shafts175
Counter Gear Needle Bearings176
Counter Gear Assembly176
Counter Gear Stopper Pin176
Transfer Case Covers177
Lubricating Oil for Transfer Gear177
Propeller Shafts: Contents178
Propeller Shafts: Description179
Propeller Shafts: Removal180
Propeller Shafts: Maintenance Services180
Universal Joint Noise180
Propeller Shafts Installation183
Differential: Contents184
Differential: Description185
Differential: Removal186
Differential Disassembly188
Differential Maintenance Services189
Side Gear Backlash189
Determination of Shim Thickness for Bevel Pinion190
Bevel Pinion Bearing Preload Adjustment191
Bevel Gear Backlash Adjustment192
Pinion-To-Gear Tooth Contact Pattern Check and Adjustment193
Differential Reassembly Instructions195
Drive Bevel Gear Bolts195
Bevel Pinion Bearings195
Differential Side Bearings195
Side Bearing Caps196
Differential Gear Oil196
Suspension: Contents198
Suspension: Description199
Barfield Joint Construction and Operation200
Removal of Front Wheel and Kuckle201
Suspension: Maintenance Services202
Barfield Joint202
Kingpins202
Oil Seal203
Suspension: Important Steps in Reassembly204
Wheel Spindle, Knuckle204
Shock Absorbers and Leaf Spring Specifications205
Shock Absorbers and Leaf Spring Tips on Installation206
Steering System: Contents207
Steering System: Description, Specifications and Data208
Steering Gear Box Construction and Operation209
Steering Handwheel, Steering Shaft, Gear Box Removal210
Steering System: Maintenance Services211
Steering Handwheel Play211
Steering Gear Box211
Steering Rubber Joint212
Wheel and Hub Nuts212
Steering Tie Rod Lever and Tie Rod212
Tires212
Steering System: Important Step in Reassembly213
Tie Rod Turnbuckles, Steering Handwheel213
Steering Column Cover Clearances214
Wheel Alignment214
Alignment Service Data214
Brakes: Contents215
Brakes: Description216
Tandem Master Cylinder217
Tandem Master Cylinder Operation217
Front/Rear Brake Construction219
Center Brake Construction219
Brake: Maintenance Services220
Wheel Cylinder Construction220
Brake Drum220
Brake Shoes, Brake Pipes, Air Purging221
Master Cylinder and Wheel Cylinders221
Brake Fluid, Brake Pedal222
Brake Shoe Clearance Adjustment222
Parking Brake Lever222
Parking Brake Cable223
Brake Hoses and Pipes223
Door: Contents224
Door: Description225
Door Assembly (LJ80V)226
Door Inspection and Adjustments (LJ80V)228
Outside Door Handle228
Door Lock Striker228
Window Regulator228
Door Window Glass229
Body Electrical Equipment: Contents230
Wiring Diagram231
Headlight Wiring Circuit233
Headlight Beam Setting233
Headlight Beam Maintenance234
Turn Signal Light and Hazard Warning Light: Circuit Description235
Windshield Wiper Motor Circuit Description236
Turn Signal Light and Hazard Warning Light: Inspection236
Windshield Wiper Motor Maintenance237
Fuel Gauge: Circuit Description, Inspection238
Service Data and Maintenance Schedule: Contents239
Engine Service Data240
Cooling System Service Data243
Differential Service Data243
Suspension Service Data244
Steering System Service Data245
Tire Service Data246
Brake Service Data247
Electrical Service Data248
Capacity Service Data252
Tightening Torque: Engine253
Tightening Torque: Transmission257
Tightening Torque: Transfer Gear Box258
Tightening Torque: Differential260
Tightening Torque: Suspension261
Tightening Torque: Steering263
Tightening Torque: Brake265
Periodic Maintenance268
Lj81270
LJ81 Specifications272
Camshaft Timing Belt279
Transfer Input Shaft Bearing Retainer Shim281
Input Shaft Bearing Retainer282
Air Cleaner289
Starting Motor290
Important Reminder for Starter Motor Reassembly294
Shift Lever, Yoke295
Armature295
Starter Magnetic Switch295

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