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Daihatsu Sportrak F300 1987-1998 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Sportrak Generation: F300 Model Years: 1987-1998 Codes Chassis Code: F300 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-road Utility Vehicle Target Audience: Enthusiasts seeking robust, capable, and simple off-road vehicles; budget-conscious buyers looking for durable utility. Competitive Analysis Key Competitors: Suzuki Samurai, Jeep Wrangler (early models), Toyota Hilux Surf (early models), Mitsubishi Pajero/Montero (early models). Key Features Drivetrain Capability: Body-on-frame construction, selectable 4WD (often with low-range gearing), solid axles (rear, often front too), designed for off-road prowess and utility. Simplicity And Durability: Known for its straightforward mechanicals, making it relatively easy to maintain and repair, contributing to its longevity. Versatility: Often available in different body styles (hardtop, soft-top, pickup), catering to various utility and recreational needs. 📋 Manual Details Coverage Areas Primary Focus: Service, Repair, Workshop Key Systems Covered: Engine Mechanical, Engine Fuel, Engine Cooling, Engine Lubrication, Engine Electrical, Transmission (Manual & Automatic), Drivetrain (4WD System), Suspension, Steering, Brakes, Body Electrical, Body & Frame, Heating & Air Conditioning, Emissions Control Page Count Estimated Page Count: 500+ Manual Type Type: Comprehensive Service & Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, and reassembly procedures for cylinder head, blocks, pistons, connecting rods, crankshafts, camshafts, valve trains, and timing components. Engine Fuel System: Carburetor systems (various models), fuel injection systems (if applicable), fuel pump, fuel filter, and fuel lines. Engine Cooling System: Radiator, fan, water pump, thermostat, hoses, and coolant specifications. Engine Lubrication System: Oil pump, oil filter, oil pan, oil specifications, and lubrication points. Engine Electrical System: Ignition system (distributor, coil, spark plugs), starter motor, alternator, battery, wiring diagrams, fuses, and relays. Transmission Manual: Clutch system, gearbox disassembly, assembly, gear shift mechanisms, and fluid specifications. Transmission Automatic: Internal components, torque converter, valve body, and fluid specifications (if applicable to certain trims/engines). Drivetrain 4Wd: Transfer case operation and repair, front and rear axle assemblies, drive shafts, U-joints, and hubs. Suspension System: Front and rear suspension components (leaf springs, shock absorbers, control arms, bushings), alignment specifications. Steering System: Steering column, steering gear box, power steering pump and system (if equipped), tie rods, and steering linkage. Brake System: Front and rear brake types (drum/disc), master cylinder, brake lines, calipers/wheel cylinders, brake fluid specifications, and bleeding procedures. Body Electrical: Lighting system, wipers, washers, horn, power windows/locks (if equipped), interior lighting, and instrument cluster. Body And Frame: Body panel removal and installation, door mechanisms, interior trim, seat adjustments, chassis specifications. Heating And Air Conditioning: HVAC system components, blower motor, heater core, A/C compressor, refrigerant, and operation. Emissions Control: Catalytic converter, EGR system, and emission control devices relevant to the model years. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspections. Troubleshooting Diagnostics: Systematic diagnostic procedures for common drivability issues, electrical faults, and mechanical problems. Component Repair: Detailed step-by-step instructions for removing, repairing, and reinstalling major and minor vehicle components. Major Overhaul: Guidelines for engine and transmission overhauls, including component measurements and tolerances. Electrical Troubleshooting: Use of wiring diagrams for diagnosing and repairing electrical circuits and components. Specifications And Tolerances: Torque values, clearances, measurements, and other critical technical data for proper assembly and adjustment. Technical Depth Depth Of Coverage: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers detailed diagnostics, component replacement, and major repairs. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Likely text-searchable for quick access to information. Print Quality Image Resolution: Designed for clarity of diagrams and technical illustrations. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Family: Daihatsu F-series (e.g., F50, F60, F80, F100, F200) Common Engine Displacement: 1.3L (1300cc) and 1.6L (1600cc) inline-4 cylinders Engine Layout: Inline-4, typically SOHC Performance Horsepower Range: Approximately 65-95 hp (depending on specific engine and market) Torque Range: Approximately 80-115 lb-ft (depending on specific engine and market) Fuel System Fuel Delivery: Primarily Carburetor (e.g., Aisan, Mikuni), with some later models potentially having fuel injection. Recommended Fuel: Unleaded Gasoline (Octane rating typically 87 or higher) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 3-speed or 4-speed Automatic Transmission (less common, often on higher trims or later models) Features Drivetrain Configuration: Part-time 4-wheel drive with selectable 2WD/4WD and often a transfer case with high/low range. 📐 Dimensions Exterior Length: Approx. 3.7 - 3.9 meters (depending on body style and specific model) Width: Approx. 1.5 - 1.6 meters Height: Approx. 1.7 - 1.8 meters Weights Curb Weight: Approx. 1000 - 1200 kg Gross Vehicle Weight Rating: Varies by model, typically around 1600-1800 kg 🛡️ Safety Features Ratings Crash Test Data: Limited official crash test data available for this era and segment, particularly from major agencies like NHTSA or IIHS. Safety features were basic. Active Features Active...
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Daihatsu Sportrak F300 1987-1998 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Sportrak
Generation:
F300
Model Years:
1987-1998
Codes
Chassis Code:
F300
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Off-road Utility Vehicle
Target Audience:
Enthusiasts seeking robust, capable, and simple off-road vehicles; budget-conscious buyers looking for durable utility.
Competitive Analysis
Key Competitors:
Suzuki Samurai, Jeep Wrangler (early models), Toyota Hilux Surf (early models), Mitsubishi Pajero/Montero (early models).
Key Features
Drivetrain Capability:
Body-on-frame construction, selectable 4WD (often with low-range gearing), solid axles (rear, often front too), designed for off-road prowess and utility.
Simplicity And Durability:
Known for its straightforward mechanicals, making it relatively easy to maintain and repair, contributing to its longevity.
Versatility:
Often available in different body styles (hardtop, soft-top, pickup), catering to various utility and recreational needs.
📋 Manual Details
Coverage Areas
Primary Focus:
Service, Repair, Workshop
Key Systems Covered:
Engine Mechanical, Engine Fuel, Engine Cooling, Engine Lubrication, Engine Electrical, Transmission (Manual & Automatic), Drivetrain (4WD System), Suspension, Steering, Brakes, Body Electrical, Body & Frame, Heating & Air Conditioning, Emissions Control
Page Count
Estimated Page Count:
500+
Manual Type
Type:
Comprehensive Service & Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, and reassembly procedures for cylinder head, blocks, pistons, connecting rods, crankshafts, camshafts, valve trains, and timing components.
Engine Fuel System:
Carburetor systems (various models), fuel injection systems (if applicable), fuel pump, fuel filter, and fuel lines.
Engine Cooling System:
Radiator, fan, water pump, thermostat, hoses, and coolant specifications.
Engine Lubrication System:
Oil pump, oil filter, oil pan, oil specifications, and lubrication points.
Engine Electrical System:
Ignition system (distributor, coil, spark plugs), starter motor, alternator, battery, wiring diagrams, fuses, and relays.
Transmission Manual:
Clutch system, gearbox disassembly, assembly, gear shift mechanisms, and fluid specifications.
Transmission Automatic:
Internal components, torque converter, valve body, and fluid specifications (if applicable to certain trims/engines).
Drivetrain 4Wd:
Transfer case operation and repair, front and rear axle assemblies, drive shafts, U-joints, and hubs.
Suspension System:
Front and rear suspension components (leaf springs, shock absorbers, control arms, bushings), alignment specifications.
Steering System:
Steering column, steering gear box, power steering pump and system (if equipped), tie rods, and steering linkage.
Brake System:
Front and rear brake types (drum/disc), master cylinder, brake lines, calipers/wheel cylinders, brake fluid specifications, and bleeding procedures.
Body Electrical:
Lighting system, wipers, washers, horn, power windows/locks (if equipped), interior lighting, and instrument cluster.
Body And Frame:
Body panel removal and installation, door mechanisms, interior trim, seat adjustments, chassis specifications.
Heating And Air Conditioning:
HVAC system components, blower motor, heater core, A/C compressor, refrigerant, and operation.
Emissions Control:
Catalytic converter, EGR system, and emission control devices relevant to the model years.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspections.
Troubleshooting Diagnostics:
Systematic diagnostic procedures for common drivability issues, electrical faults, and mechanical problems.
Component Repair:
Detailed step-by-step instructions for removing, repairing, and reinstalling major and minor vehicle components.
Major Overhaul:
Guidelines for engine and transmission overhauls, including component measurements and tolerances.
Electrical Troubleshooting:
Use of wiring diagrams for diagnosing and repairing electrical circuits and components.
Specifications And Tolerances:
Torque values, clearances, measurements, and other critical technical data for proper assembly and adjustment.
Technical Depth
Depth Of Coverage:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers detailed diagnostics, component replacement, and major repairs.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Likely text-searchable for quick access to information.
Print Quality
Image Resolution:
Designed for clarity of diagrams and technical illustrations.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Daihatsu F-series (e.g., F50, F60, F80, F100, F200)
Common Engine Displacement:
1.3L (1300cc) and 1.6L (1600cc) inline-4 cylinders
Engine Layout:
Inline-4, typically SOHC
Performance
Horsepower Range:
Approximately 65-95 hp (depending on specific engine and market)
Torque Range:
Approximately 80-115 lb-ft (depending on specific engine and market)
Fuel System
Fuel Delivery:
Primarily Carburetor (e.g., Aisan, Mikuni), with some later models potentially having fuel injection.
Recommended Fuel:
Unleaded Gasoline (Octane rating typically 87 or higher)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
3-speed or 4-speed Automatic Transmission (less common, often on higher trims or later models)
Features
Drivetrain Configuration:
Part-time 4-wheel drive with selectable 2WD/4WD and often a transfer case with high/low range.
📐 Dimensions
Exterior
Length:
Approx. 3.7 - 3.9 meters (depending on body style and specific model)
Width:
Approx. 1.5 - 1.6 meters
Height:
Approx. 1.7 - 1.8 meters
Weights
Curb Weight:
Approx. 1000 - 1200 kg
Gross Vehicle Weight Rating:
Varies by model, typically around 1600-1800 kg
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official crash test data available for this era and segment, particularly from major agencies like NHTSA or IIHS. Safety features were basic.
Active Features
Active Safety Features:
Four-wheel drive system for enhanced traction.
Passive Features
Passive Safety Features:
Seat belts, basic frame construction. Optional features like roll bars on some soft-top models.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio, often with a cassette player. Speaker count typically limited (e.g., 2 or 4).
Driver Assistance
Driver Assistance Features:
Virtually none by modern standards. Focus is on mechanical simplicity.
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 miles or 3-6 months, whichever comes first (depending on usage and oil type).
Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 15,000-30,000 miles or annually.
Spark Plug Replacement:
Every 20,000-30,000 miles (depending on plug type).
Transmission Fluid Change:
Every 30,000-60,000 miles (manual and automatic, consult specific manual for exact interval).
Coolant Flush And Replace:
Every 2-3 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 recommended (check manual for ambient temperature suitability).
Engine Oil Capacity:
Approx. 3.5 - 4.0 liters (with filter, depending on engine variant).
Transmission Fluid Type Manual:
GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Type Automatic:
Dexron II or equivalent.
Coolant Type:
Ethylene glycol-based, pre-mixed 50/50 with distilled water. Green or orange color depending on formulation.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Carburetor Tuning:
Carburetors can be sensitive to age and require regular adjustment/cleaning for optimal performance and fuel economy.
Rust And Corrosion:
As with many vehicles of this era, especially those used off-road or in humid climates, rust can be a concern, particularly on the chassis, body panels, and around wheel wells.
Suspension Bushings:
Worn suspension bushings (leaf spring eyes, control arm bushings) can lead to a rougher ride and alignment issues.
4Wd System Maintenance:
Regular lubrication and inspection of the transfer case and axle components are crucial to prevent wear.
Heater Core:
Potential for heater core leaks or blockages, affecting cabin heating.
📚 Vehicle History
Brand Heritage
Daihatsu Specialty:
Daihatsu is renowned for producing small, economical, and durable vehicles, particularly kei cars and compact SUVs, with a strong reputation for reliability in many Asian markets.
Model Evolution
Sportrak Lineage:
The Sportrak (also known as Rocky in some markets) was Daihatsu's entry into the compact, rugged, off-road oriented SUV segment. It shared mechanical underpinnings with other Daihatsu utility vehicles.
F300 Generation:
The F300 generation represented a significant update from its predecessors, offering improved styling, powertrains, and amenities, while retaining its core off-road capabilities.
Production
Production Period:
1987-1998
Manufacturing Locations:
Primarily Japan
🏆 Awards & Recognition
Recognitions
Off Road Capability Recognition:
Recognized for its surprisingly adept off-road capabilities relative to its size and price point, often favored by enthusiasts for its ruggedness.
Ratings
Reliability Perception:
Generally perceived as reliable due to its simple mechanical design, though age-related component wear is common.
Certifications
Certification Status:
No prominent awards or certifications typically associated with this model; its value lies in its utility and off-road performance.
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