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Suzuki RA410 User Manual

Suzuki RA410
761 pages
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IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special mean-
ings. Pay special attention to the messages high-
lighted by these signal words.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for autho-
rized Suzuki dealers and qualified service
mechanics only. Inexperienced mechanics
or mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle un-
safe for the driver and passengers.
WARNING:
For vehicles equipped with a Supplemental
Restraint Air Bag System:
Service on and around the air bag system
components or wiring must be performed
only by an authorized SUZUKI dealer.
Please observe all WARNINGS and CAU-
TIONS in SECTION 10B and Precautions,
Air Bag System Components and Wiring
Location View in SECTION 10B or before
performing service on or around the air
bag system components or wiring. Failure
to follow WARNINGS could result in
unintentional activation of the system or
could render the system inoperative. Ei-
ther of these two conditions may result in
severe injury.
If the air bag system and another vehicle
system both need repair, Suzuki recom-
mends that the air bag system be repaired
first, to help avoid unintended air bag de-
ployment.
Do not modify the steering wheel, instru-
ment panel or any other air bag system
component (on or around air bag system
components or wiring). Modifications can
adversely affect air bag system perfor-
mance and lead to injury.
If the vehicle will be exposed to tempera-
tures over 93C (200F) (for example, dur-
ing a paint baking process), remove the
air bag system components (air bag (infla-
tor) modules, SDM and/or seatbelt with
pretensioner) beforehand to avoid com-
ponent damage or unintended deploy-
ment.

Table of Contents

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Suzuki RA410 Specifications

General IconGeneral
BrandSuzuki
ModelRA410
CategoryAutomobile
LanguageEnglish

Summary

Important Safety Warnings and Information

WARNING/CAUTION/NOTE Definitions

Explains the meaning of signal words like WARNING, CAUTION, and NOTE.

Warnings for Authorized Service Personnel

States that the service manual is intended for authorized Suzuki dealers and qualified mechanics only.

Air Bag System Precautions

Outlines critical safety precautions for servicing vehicles equipped with a Supplemental Restraint Air Bag System.

Foreword

Manual Scope and Applicable Model

Describes the manual's content and the applicable vehicle model (RA410).

Manual Organization and Usage

Explains how the manual is organized into sections and the importance of observing specified items.

Service Materials Recommendation

Recommends using genuine Suzuki parts, tools, and service materials.

Manual Information Basis and Revisions

States that information is based on the latest product information available at the time of publication approval.

Related Manuals

Lists related manuals, such as the Wiring Diagram Manual.

General Information

How to Use This Manual

Provides guidance on navigating and utilizing the service manual effectively.

Precautions for Air Bag System

Details critical safety precautions for servicing vehicles equipped with a Supplemental Restraint (Air Bag) System.

Servicing and Handling Air Bag Components

Provides detailed instructions and warnings for handling and storing air bag modules and related components.

SDM Handling and Precautions

Outlines specific handling and safety precautions for the Sensing and Diagnostic Module (SDM).

Driver and Passenger Seat Belt Pretensioners Precautions

Details handling and safety precautions for seat belt pretensioners.

General Precautions

Lists general safety precautions applicable to various service procedures.

Precautions for Electrical Circuit Service

Provides guidelines for safely performing service on electrical circuits and components.

Electrical Circuit Inspection Procedure

Outlines general methods for checking open and short circuits using an ohmmeter and voltmeter.

Intermittent and Poor Connection Issues

Discusses common causes of intermittent electrical issues and how to check them.

Vehicle Lifting Points

Provides essential safety information and procedures for lifting the vehicle.

Metric Information

Details metric fastener specifications and standard tightening torques.

Maintenance and Lubrication

Maintenance Schedule

Provides a schedule of maintenance services based on mileage or time intervals.

Engine Oil and Filter Change

Provides procedures for changing engine oil and filter, including warnings and cautions.

Engine Coolant Change

Details the procedure for changing engine coolant, including warnings.

Brake System Items

Details inspection procedures for brake discs, pads, drums, shoes, hoses, and pipes.

Manual Transmission Oil Inspection and Change

Provides procedures for inspecting and changing manual transmission oil.

Heater and Ventilation

General Description of Heater and Ventilation

Describes the construction and function of the heater and ventilation system.

Heater Unit

Details the components of the heater unit.

Diagnosis Table for Heater and Ventilation

Provides a table for diagnosing common issues with the heater and ventilation system.

On-Vehicle Service: Blower Motor

Details the removal, inspection, and installation procedures for the blower motor.

Heater Control Lever Assembly Removal

Outlines the steps for removing the heater control lever assembly.

Air Conditioning (Optional)

General Description of Air Conditioning System

Provides an overview of the air conditioning system components and refrigerant flow.

Major Components and Location

Identifies and illustrates the locations of major air conditioning system components.

Diagnosis Table for Air Conditioning System

Offers a comprehensive table for diagnosing common air conditioning system problems and their causes/corrections.

Quickly Checking of Refrigerant Charge

Describes a method for quickly checking the refrigerant charge in the A/C system.

Troubleshooting Procedure Using Manifold Gauge Set

Explains how to use a manifold gauge set for troubleshooting cooling problems.

Compressor Removal and Installation

Provides instructions for removing and installing the air conditioning compressor.

Magnet Clutch Removal and Installation

Covers the removal and installation of the magnet clutch.

Performance Test

Outlines the procedure for testing the air conditioning system performance under various conditions.

Steering, Suspension, Wheels and Tires

Diagnosis Table for Steering, Suspension, and Wheels

Lists common steering, suspension, and wheel-related complaints, possible causes, and corrections.

Tire Diagnosis

Covers diagnosis of irregular and premature tire wear, wear indicators, radial tire waddle, and radial tire lead.

Front End Alignment

Explains the general description, alignment service data, toe setting, and camber.

Toe Adjustment

Details the procedure for adjusting the toe-in of the front wheels.

Manual Rack and Pinion

Provides general description and contents for the manual rack and pinion system.

Steering Wheel Check

Guides on how to check the steering wheel for looseness or rattle.

Steering Rack Boot Check

Explains how to inspect steering rack boots for tears.

Tie Rod End Boot Check

Inspects each boot for tear, replacing if a small tear is noted.

Steering Shaft Joint Check

Checks shaft joint for wear, breakage, and other damage.

Tie Rod End Check

Inspects tie rod ends for play in the ball joint.

Manual Rack and Pinion Assembly (Steering Gear Case) Removal

Outlines the procedure for removing the steering gear case assembly.

Disassembly of Manual Rack and Pinion

Details the step-by-step process for disassembling the manual rack and pinion.

Inspection of Steering Components

Covers inspection of the rack plunger, steering pinion, and steering rack.

Front Suspension Inspection

Details inspection procedures for the front suspension system components.

Wheel Hub and Steering Knuckle Removal

Provides instructions for removing the wheel hub and steering knuckle.

Disassembly of Wheel Hub and Steering Knuckle

Covers the disassembly process for the wheel hub and steering knuckle.

Assembly of Wheel Hub and Steering Knuckle

Outlines the procedures for assembling the wheel hub and steering knuckle.

Stabilizer Bar and/or Bushings Removal

Details the procedure for removing the stabilizer bar and/or bushings.

Installation of Stabilizer Bar and Bushings

Covers the installation of the stabilizer bar and bushings.

Rear Suspension Diagnosis

Provides a diagnosis table for rear suspension issues.

Rear Shock Absorber Removal and Installation

Covers the removal and installation of the rear shock absorber.

Coil Spring Removal and Installation

Details the procedures for removing and installing the coil spring.

Bump Stopper Removal and Installation

Covers the removal and installation of the bump stopper.

Trailing Arm Removal and Installation

Provides instructions for removing and installing the trailing arm.

Rear Axle Removal and Installation

Details the procedures for removing and installing the rear axle.

Wheel Bearing and Wheel Stud Removal and Installation

Covers the removal and installation of wheel bearings and wheel studs.

Manual Transmission

General Description of Manual Transmission

Provides an overview of the manual transmission and its components.

Gear Shift Mechanism

Explains the operation of the gear shifting control system.

Diagnosis Table for Manual Transmission

Lists common manual transmission issues, possible causes, and corrections.

On-Vehicle Service: Oil Change

Details the procedure for changing the transmission oil.

Differential Side Oil Seal Replacement

Covers the replacement of the differential side oil seal.

Gear Shift Control Lever and Cable

Details the components and procedure for the gear shift control lever and cable.

Vehicle Speed Sensor (VSS) Removal and Installation

Provides instructions for removing and installing the Vehicle Speed Sensor (VSS).

Transmission Assembly Dismounting

Outlines the steps for dismounting the transmission assembly.

Remounting of Transmission Assembly

Details the procedure for remounting the transmission assembly.

Sub Assembly Service: Oil Pump

Covers the disassembly and inspection of the oil pump.

Right Case Disassembly and Reassembly

Details the disassembly and reassembly of the right case.

Left Case Disassembly and Reassembly

Covers the disassembly and reassembly of the left case.

Input Shaft Assembly Disassembly

Outlines the steps for disassembling the input shaft assembly.

Inspection and Reassembly of Gears and Synchronizer Sleeves

Details the inspection and reassembly of gears and synchronizer components.

Countershaft Assembly Disassembly

Covers the disassembly of the countershaft assembly.

Differential Assembly Disassembly

Covers the disassembly process for the differential assembly.

Adjustment and Reassembly of Differential Gear

Details the adjustment and reassembly of the differential gear, including thrust play measurement.

Reassembly of Transmission Components

Provides instructions for reassembling various transmission components.

Required Service Materials for Manual Transmission

Lists required service materials for manual transmission service.

Special Tools for Manual Transmission

Lists special tools required for manual transmission service.

Automatic Transmission

General Description of Automatic Transmission

Provides an overview of the automatic transmission and its operation.

Electric Shift Control System

Explains the operation of the electric shift control system and the Power Train Control Module (PCM).

Clutch/Brake Functions

Details the functions of the clutch and brake components within the automatic transmission.

Table of Component Operation

Illustrates which transmission components are engaged in different gear positions.

Automatic Shift Diagram

Shows the gear change points based on throttle opening and vehicle speed.

Diagnosis Table for Automatic Transmission

Lists common automatic transmission issues, possible causes, and corrections.

Stall Test

Details the procedure for checking overall transmission and engine performance by measuring stall speed.

Line Pressure Test

Explains how to check fluid pressure in the automatic transmission.

Time Lag Test

Describes a test to check clutch engagement and fluid pressure response time.

Road Test

Outlines the procedure for checking upshift and downshift behavior while driving.

On-Board Diagnosis (Self Diagnosis)

Explains the PCM's on-board diagnostic system for detecting malfunctions.

Malfunction Indicator Lamp (“Check Engine” Light) Circuit Check

Covers how to check the circuit for the Malfunction Indicator Lamp (MIL).

Diagnostic Trouble Code (DTC) Check

Details how to check for Diagnostic Trouble Codes (DTCs) in the air bag system.

Diagnostic Trouble Code (DTC) Clearance

Outlines the procedure for clearing DTCs from the air bag system.

Diagnostic Trouble Code (DTC) Table

Lists DTCs related to the air bag system with their modes and diagnosis.

DTC 41 – Shift Solenoid-A Circuit

Troubleshoots issues related to the Shift Solenoid-A circuit.

DTC 42 – Shift Solenoid-B Circuit

Details troubleshooting steps for the Shift Solenoid-B circuit.

DTC 46 – Transmission Range Switch Circuit

Covers troubleshooting for the Transmission Range Switch circuit.

Required Service Materials for Automatic Transmission

Lists required service materials for automatic transmission service.

Special Tools for Automatic Transmission

Lists special tools required for automatic transmission service.

Clutch

General Description of Clutch System

Describes the clutch as a diaphragm-spring type dry single disc system.

Diagnosis Table for Clutch Issues

Lists common clutch problems, possible causes, and corrections.

On-Vehicle Service: Clutch Pedal

Covers clutch pedal stroke adjustment and free travel inspection.

Clutch Cable Removal and Installation

Details the procedures for removing and installing the clutch cable.

Unit Repair Overhaul: Clutch Cover, Clutch Disc and Flywheel

Covers the removal, inspection, and installation of clutch cover, disc, and flywheel.

Inspection of Clutch Components

Details inspection of input shaft bearing, clutch disc, and clutch cover.

Installation of Clutch Components

Provides instructions for installing clutch components like flywheel, input shaft bearing, and clutch cover.

Clutch Release System Removal

Outlines the procedure for removing the clutch release arm, bearing, and shaft.

Clutch Release Bearing Inspection

Details how to inspect the clutch release bearing for smooth rotation.

Clutch Release Shaft Inspection

Covers inspection of the clutch release shaft and its pin for deflection or damage.

Installation of Clutch Release Shaft Components

Provides instructions for installing clutch release shaft components, including bushes and seals.

Body Electrical System

General Description of Body Electrical System

Describes the vehicle's electrical components operating on 12 Volts and negative ground polarity.

Cautions in Servicing Electrical Systems

Provides critical safety cautions for working with electrical systems to prevent damage and fire.

Wiring Color Symbols

Explains the wire color abbreviations used in wiring diagrams.

Combination Meter

Details the terminal arrangement and inspection of the combination meter.

Diagnosis for Exterior and Interior Lights

Provides a diagnosis table for headlight issues.

Turn Signal and Hazard Warning Lights

Covers diagnosis for turn signal and hazard warning light malfunctions.

Clearance, Tail and License Plate Lights

Details diagnosis for clearance, tail, and license plate light issues.

Back-up Light Trouble Diagnosis

Covers diagnosis for back-up light malfunctions.

Brake Lights Trouble Diagnosis

Details diagnosis for brake light malfunctions.

Speedometer and VSS Diagnosis

Covers diagnosis for speedometer and Vehicle Speed Sensor (VSS) issues.

Fuel Meter and Fuel Level Sensor (Gauge Unit) Diagnosis

Details diagnosis for fuel meter and fuel level sensor issues.

Engine Coolant Temp. (ECT) Meter and ECT Sensor Diagnosis

Covers diagnosis for the engine coolant temperature meter and sensor.

Oil Pressure Warning Light Diagnosis

Details diagnosis for the oil pressure warning light.

Brake and Parking Brake Warning Light Diagnosis

Covers diagnosis for brake and parking brake warning lights.

Rear Window Defogger (If Equipped) Diagnosis

Details diagnosis for the rear window defogger system.

Wipers and Washers

Covers diagnosis for wiper and washer malfunctions.

Power Window Control System (If Equipped) Power Window Main Switch Inspection

Covers inspection of the power window main switch continuity.

Front Door Glass Removal and Installation

Outlines the procedure for removing the front door glass.

Front Door Window Regulator Removal and Installation

Outlines the removal and installation of the front door window regulator.

Windshield Removal and Installation

Details the procedure for removing and installing the windshield, including adhesive application.

Sealant Application Area

Illustrates areas where sealant should be applied for body sealing.

Plastic Parts Finishing Painting

Discusses painting procedures for plastic parts.

Security and Locks Front Door Lock Assembly Removal and Installation

Covers removal and installation of the front door lock assembly.

Rear Door Lock Assembly Removal and Installation

Details removal and installation of the rear door lock assembly.

Back Door Assembly Removal and Installation

Provides instructions for removing and installing the back door lock assembly.

Key Coding Key Usage and Identification

Explains how to use and identify key codes for ignition and door locks.

Electrical Diagnosis

Directs users to Section 8 for ignition switch electrical troubleshooting.

Restraint System

General Description of Air Bag System

Describes the air bag system components, including airbags and seat belt pretensioners.

Seat Belt with ELR and Pretensioner

Explains the operation of seat belts with ELR and pretensioner mechanisms.

Seat Belt Pretensioner (If Equipped)

Details the function and activation of the seat belt pretensioner unit.

Seat Belt Diagnosis

Refers to Section 10B for seat belt pretensioner diagnosis.

Inspection and Repair Required After an Accident

Outlines checks and repairs required after an accident, especially concerning air bag components.

Service Precautions

Lists critical safety precautions and procedures to follow when servicing seat belts and the air bag system.

Disabling Air Bag System

Details the procedure for disabling the air bag system before service.

Enabling Air Bag System

Explains how to enable the air bag system after service.

Handling and Storage (for Seat Belt with Pretensioner)

Provides guidelines for handling and storing seat belts with pretensioners.

Disposal (for Seat Belt with Pretensioner)

Refers to procedures for disposing of seat belt pretensioners.

Front Seat Belt Without Pretensioner Removal

Outlines the procedure for removing front seat belts without pretensioners.

Front Seat Belt with Pretensioner Removal

Details the procedure for removing front seat belts with pretensioners.

Seat Belt Inspection

Covers inspection of seat belts and their components for damage and proper function.

Installation of Front Seat Belts

Provides instructions for installing front seat belts, including tightening torques.

Seat Belt Pretensioner Inspection

Details inspection procedures for the seat belt pretensioner.

Rear Seat Belt Removal, Inspection, and Installation

Covers removal, inspection, and installation of rear seat belts.

Air Bag System Diagnostic System Check

Explains the process of performing an air bag system diagnostic check.

Diagnostic Trouble Codes (DTC) Check

Details how to check for Diagnostic Trouble Codes (DTCs) in the air bag system.

Diagnostic Trouble Code (DTC) Clearance

Outlines the procedure for clearing DTCs from the air bag system.

Diagnostic Trouble Code (DTC) Table

Lists DTCs related to the air bag system with their modes and diagnosis.

Table A – Air Bag Warning Lamp Comes on Steady Without Flashing

Provides a diagnostic flow table for when the Air Bag warning lamp is steady.

Table B – Air Bag Warning Lamp Does Not Come On

Offers a diagnostic flow table for when the Air Bag warning lamp does not illuminate.

Table C – Air Bag Warning Lamp Flashes

Provides a diagnostic flow table for when the Air Bag warning lamp flashes.

Table D – Air Bag Warning Lamp Cannot Indicate DTC by Flashing

Outlines diagnostic steps when the Air Bag warning lamp cannot indicate DTCs by flashing.

DTC 15 – Passenger Air Bag Initiator Circuit Resistance High

Troubleshoots issues related to high resistance in the passenger air bag initiator circuit.

DTC 16 – Passenger Air Bag Initiator Circuit Resistance Low

Details troubleshooting for low resistance in the passenger air bag initiator circuit.

DTC 18 – Passenger Air Bag Initiator Circuit Short to Ground

Covers troubleshooting for short to ground faults in the passenger air bag initiator circuit.

DTC 19 – Passenger Air Bag Initiator Circuit Short to Power Circuit

Outlines troubleshooting for short to power circuit faults in the passenger air bag initiator circuit.

DTC 21 – Driver Air Bag Initiator Circuit Resistance High

Troubleshoots issues related to high resistance in the driver air bag initiator circuit.

DTC 22 – Driver Air Bag Initiator Circuit Resistance Low

Details troubleshooting for low resistance in the driver air bag initiator circuit.

DTC 24 – Driver Air Bag Initiator Circuit Short to Ground

Covers troubleshooting for short to ground faults in the driver air bag initiator circuit.

DTC 25 – Driver Air Bag Initiator Circuit Short to Power Circuit

Outlines troubleshooting for short to power circuit faults in the driver air bag initiator circuit.

DTC 31 – Power Source Voltage High

Details troubleshooting for high power source voltage issues.

DTC 31 – Power Source Voltage High Diagnostic Flow Table

Provides a diagnostic flow table for DTC 31 (Power Source Voltage High).

DTC 32 – Power Source Voltage Low

Details troubleshooting for low power source voltage issues.

DTC 41 – Driver Pretensioner Initiator Circuit Resistance High

Troubleshoots high resistance in the driver pretensioner initiator circuit.

DTC 45 – Passenger Pretensioner Initiator Circuit Resistance High

Covers troubleshooting for high resistance in the passenger pretensioner initiator circuit.

DTC 42 – Driver Pretensioner Initiator Circuit Resistance Low

Details troubleshooting for low resistance in the driver pretensioner initiator circuit.

DTC 46 – Passenger Pretensioner Initiator Circuit Resistance Low

Outlines troubleshooting for low resistance in the passenger pretensioner initiator circuit.

DTC 43 – Driver Pretensioner Initiator Circuit Short to Ground

Troubleshoots short to ground faults in the driver pretensioner initiator circuit.

DTC 47 – Passenger Pretensioner Initiator Circuit Short to Ground

Covers troubleshooting for short to ground faults in the passenger pretensioner initiator circuit.

DTC 44 – Driver Air Bag Initiator Circuit Short to Power Circuit

Details troubleshooting for short to power circuit faults in the driver air bag initiator circuit.

DTC 48 – Passenger Air Bag Initiator Circuit Short to Power Circuit

Outlines troubleshooting for short to power circuit faults in the passenger air bag initiator circuit.

DTC 51, 53 – Frontal Crash Detected (System Activation Command Outputted)

Covers diagnosis when a frontal crash is detected, leading to system activation command.

Diagnostic Flow Table: DTC 51, 53 – Frontal Crash Detected

Provides a diagnostic flow table for DTC 51 and 53 related to frontal crash detection.

Repairs and Inspections Required After an Accident

Details necessary repairs and inspections following a vehicle accident, especially concerning air bag components.

Accident with Deployment/Activation – Component Replacement

Lists components that must be replaced after an air bag system deployment or activation.

Accident with or Without Deployment/Activation – Component Inspections

Outlines inspections required for air bag system components after a crash, regardless of deployment.

Air Bag Wire Harness and Connectors Inspection

Details inspection of air bag wire harness and connectors for damage or poor connections.

Disposal of Air Bag (Inflator) Modules and Seat Belt Pretensioner Disposal

Provides critical safety information and procedures for the proper disposal of undeployed air bags and seat belt pretensioners.

Deployment/Activation Outside Vehicle

Outlines the procedure for deploying/activating air bag modules and seat belt pretensioners outside the vehicle.

Deployment/Activation Inside Vehicle

Describes the procedure for deploying/activating air bag modules and seat belt pretensioners when scrapping the vehicle.

Special Tools for Air Bag System

Lists special tools required for air bag system diagnostics and service.

Body Service

Glass and Windows and Mirrors

Covers service procedures for glass, windows, and mirrors.

Front Door Glass Removal and Installation

Details the removal and installation process for front door glass.

Front Door Window Regulator Removal and Installation

Outlines the removal and installation of the front door window regulator.

Windshield Removal and Installation

Details the procedure for removing and installing the windshield, including adhesive application.

Sealant Application Area

Illustrates areas where sealant should be applied for body sealing.

Plastic Parts Finishing Painting

Discusses painting procedures for plastic parts.

Security and Locks Front Door Lock Assembly Removal and Installation

Covers removal and installation of the front door lock assembly.

Rear Door Lock Assembly Removal and Installation

Details removal and installation of the rear door lock assembly.

Back Door Assembly Removal and Installation

Provides instructions for removing and installing the back door lock assembly.

Key Coding Key Usage and Identification

Explains how to use and identify key codes for ignition and door locks.

Electrical Diagnosis

Directs users to Section 8 for ignition switch electrical troubleshooting.

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