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Suzuki CERVO SC100 Digital Workshop Repair Manual 1977-1982

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🏷️ Basic Information Identification Make: Suzuki Model: Cervo Model Code: SC100 Year: 1977-1982 Codes Platform Code: SS80 (predecessor to Alto) 👋 Introduction Market Position Segment: Economical city car, a step up from earlier Kei cars in terms of comfort and performance Competitive Analysis Key Competitors: Daihatsu Charade, Mitsubishi Minica, Subaru R-2, Honda Life Key Features Distinguishing Features: Compact size, fuel efficiency, distinctive styling for its era, robust (for the time) F5A engine Manual Value Proposition Benefit To Owner: Empowers owners and independent mechanics with professional-level repair and maintenance information, reducing reliance on costly dealership services. Manual Usability Ease Of Use: User-friendly interface, easy navigation through sections, print-on-demand capability for specific repair tasks 📋 Manual Details Coverage Areas Coverage Continents: Global (primarily Japan, Europe, Australasia) Market Segments Covered: Kei car (Japan), Small city car (export) Page Count Estimated Page Count: Varies by specific edition, typically 300-600 pages for comprehensive coverage Manual Type Type: Digital Workshop Repair Manual Language Language: English Format Digital Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Powertrain: Engine (F5A), Transmission (3-speed Automatic, 4-speed Manual), Drivetrain Chassis: Suspension (Front MacPherson Strut, Rear Leaf Spring), Steering, Brakes (Front Disc, Rear Drum), Wheels & Tires Electrical: Wiring Diagrams, Lighting, Ignition System, Charging System, Starting System, Instrumentation, Audio System Body: Body Panels, Doors, Windows, Trim, Seats, Interior Components, HVAC (Heating, Ventilation, Air Conditioning) Procedures Included Maintenance: Fluid changes (oil, coolant, brake fluid), Filter replacements, Spark plug service, Belt adjustments, Lubrication points Diagnostics: Troubleshooting guides, Symptom analysis, Diagnostic charts, Component testing procedures Repair: Engine overhaul, Transmission rebuild, Brake system repair, Suspension component replacement, Electrical system repairs, Bodywork and panel repair Rebuilding: Detailed instructions for component disassembly, inspection, part replacement, and reassembly Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds; detailed diagnostic procedures 📊 Manual Specifications File Format Compatibility: Microsoft Windows (95 to 7), macOS Print Quality Printability: High-resolution printable pages Binding Type Digital Format Advantage: No physical binding degradation, easily searchable and reproducible Paper Type Digital Representation: Simulates high-quality paper content with clear text and images ⚙️ Engine Specifications Primary Engine Engine Code: F5A Engine Type: Inline 3-cylinder, 4-stroke Displacement: 797 cc (0.8 L) Bore X Stroke: 68.0 mm x 73.0 mm Compression Ratio: 8.4:1 or 9.0:1 (depending on market and specific variant) Valvetrain: SOHC (Single Overhead Camshaft), 2 valves per cylinder Performance Horsepower Ps: Approx. 33-37 PS (24-27 kW) at ~5500 rpm Torque Kgf-M: Approx. 5.2-5.5 kgf-m (37-40 lb-ft) at ~3000-3500 rpm Fuel System Fuel Delivery: Carburetor (e.g., Hitachi, Mikuni) Fuel Type: Unleaded gasoline (octane rating appropriate for era, typically 90-91 RON) Cooling System Cooling Type: Water-cooled 🔧 Transmission Standard Type: 4-speed Manual Optional Type: 3-speed Automatic (often referred to as 'Suzuki Automatic' or AT) Features Clutch Type: Dry single plate (Manual) Transmission Fluid Type: API GL-4 SAE 80W-90 (Manual), ATF Dexron II or equivalent (Automatic) Gear Ratios Manual Example: 1st: 3.454, 2nd: 1.947, 3rd: 1.270, 4th: 0.914, Reverse: 3.100, Final Drive: 4.090 📐 Dimensions Exterior Length Mm: 3,195 mm Width Mm: 1,395 mm Height Mm: 1,345 mm Wheelbase Mm: 2,060 mm Ground Clearance Mm: Approx. 160 mm Weights Curb Weight Kg: Approx. 570-620 kg (depending on transmission and trim) Gross Vehicle Weight Rating Kg: Approx. 1,000 kg 🛡️ Safety Features Ratings Crash Test Standards: N/A (Era-specific safety standards, likely minimal compliance with modern metrics) Active Features Braking System: Front: Ventilated Disc, Rear: Drum Parking Brake: Mechanical, rear drum Passive Features Seatbelts: Standard front seatbelts (likely 2-point or 3-point depending on market) Body Construction: Monocoque chassis with integrated safety cage elements 💡 Technology Features Infotainment Audio System: Basic AM/FM radio, optional cassette player Driver Assistance ABS: Not available Connectivity Connectivity Features: None (analog systems) 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 km or 6 months, whichever comes first Oil Filter Replacement: With every oil change Air Filter Cleaning Or Replacement: Every 10,000 km or 12 months Spark Plug Replacement: Every 20,000 km or 24 months (use NGK BP6ES or equivalent) Coolant Flush And Replace: Every 24,000 km or 24 months Fluid Specifications Engine Oil Grade: API SF/SG, SAE 10W-30 or 10W-40 (ambient temperature dependent) Engine Oil Capacity Liters: Approx. 3.0 liters (with filter change) Coolant Type: Ethylene glycol-based antifreeze/coolant, mixed 50/50 with distilled water Brake Fluid Type: DOT 3 or DOT 4 Known Issues Rust Prone Areas: Wheel arches, sills, floor pans, door bottoms (common for vehicles of this age and construction) Carburetor Issues: Clogged jets, worn diaphragms, vacuum leaks leading to rough idling or poor performance Ignition System Reliability: Points and condenser wear, coil failure, distributor issues Suspension Wear: Worn bushings, ball joints, and shock absorbers leading to clunks and poor handling Electrical Corrosion: Corrosion in connectors, grounds, and fuse box, especially in humid climates 📚 Vehicle History Brand Heritage Founding Principles: Suzuki has a long history of manufacturing small, economical...
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Suzuki CERVO SC100 Digital Workshop Repair Manual 1977-1982
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
Cervo
Model Code:
SC100
Year:
1977-1982
Codes
Platform Code:
SS80 (predecessor to Alto)
👋 Introduction
Market Position
Segment:
Economical city car, a step up from earlier Kei cars in terms of comfort and performance
Competitive Analysis
Key Competitors:
Daihatsu Charade, Mitsubishi Minica, Subaru R-2, Honda Life
Key Features
Distinguishing Features:
Compact size, fuel efficiency, distinctive styling for its era, robust (for the time) F5A engine
Manual Value Proposition
Benefit To Owner:
Empowers owners and independent mechanics with professional-level repair and maintenance information, reducing reliance on costly dealership services.
Manual Usability
Ease Of Use:
User-friendly interface, easy navigation through sections, print-on-demand capability for specific repair tasks
📋 Manual Details
Coverage Areas
Coverage Continents:
Global (primarily Japan, Europe, Australasia)
Market Segments Covered:
Kei car (Japan), Small city car (export)
Page Count
Estimated Page Count:
Varies by specific edition, typically 300-600 pages for comprehensive coverage
Manual Type
Type:
Digital Workshop Repair Manual
Language
Language:
English
Format
Digital Format:
PDF (Portable Document Format)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (F5A), Transmission (3-speed Automatic, 4-speed Manual), Drivetrain
Chassis:
Suspension (Front MacPherson Strut, Rear Leaf Spring), Steering, Brakes (Front Disc, Rear Drum), Wheels & Tires
Electrical:
Wiring Diagrams, Lighting, Ignition System, Charging System, Starting System, Instrumentation, Audio System
Body:
Body Panels, Doors, Windows, Trim, Seats, Interior Components, HVAC (Heating, Ventilation, Air Conditioning)
Procedures Included
Maintenance:
Fluid changes (oil, coolant, brake fluid), Filter replacements, Spark plug service, Belt adjustments, Lubrication points
Diagnostics:
Troubleshooting guides, Symptom analysis, Diagnostic charts, Component testing procedures
Repair:
Engine overhaul, Transmission rebuild, Brake system repair, Suspension component replacement, Electrical system repairs, Bodywork and panel repair
Rebuilding:
Detailed instructions for component disassembly, inspection, part replacement, and reassembly
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds; detailed diagnostic procedures
📊 Manual Specifications
File Format
Compatibility:
Microsoft Windows (95 to 7), macOS
Print Quality
Printability:
High-resolution printable pages
Binding Type
Digital Format Advantage:
No physical binding degradation, easily searchable and reproducible
Paper Type
Digital Representation:
Simulates high-quality paper content with clear text and images
⚙️ Engine Specifications
Primary Engine
Engine Code:
F5A
Engine Type:
Inline 3-cylinder, 4-stroke
Displacement:
797 cc (0.8 L)
Bore X Stroke:
68.0 mm x 73.0 mm
Compression Ratio:
8.4:1 or 9.0:1 (depending on market and specific variant)
Valvetrain:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
Performance
Horsepower Ps:
Approx. 33-37 PS (24-27 kW) at ~5500 rpm
Torque Kgf-M:
Approx. 5.2-5.5 kgf-m (37-40 lb-ft) at ~3000-3500 rpm
Fuel System
Fuel Delivery:
Carburetor (e.g., Hitachi, Mikuni)
Fuel Type:
Unleaded gasoline (octane rating appropriate for era, typically 90-91 RON)
Cooling System
Cooling Type:
Water-cooled
🔧 Transmission
Standard
Type:
4-speed Manual
Optional
Type:
3-speed Automatic (often referred to as 'Suzuki Automatic' or AT)
Features
Clutch Type:
Dry single plate (Manual)
Transmission Fluid Type:
API GL-4 SAE 80W-90 (Manual), ATF Dexron II or equivalent (Automatic)
Gear Ratios Manual Example:
1st: 3.454, 2nd: 1.947, 3rd: 1.270, 4th: 0.914, Reverse: 3.100, Final Drive: 4.090
📐 Dimensions
Exterior
Length Mm:
3,195 mm
Width Mm:
1,395 mm
Height Mm:
1,345 mm
Wheelbase Mm:
2,060 mm
Ground Clearance Mm:
Approx. 160 mm
Weights
Curb Weight Kg:
Approx. 570-620 kg (depending on transmission and trim)
Gross Vehicle Weight Rating Kg:
Approx. 1,000 kg
🛡️ Safety Features
Ratings
Crash Test Standards:
N/A (Era-specific safety standards, likely minimal compliance with modern metrics)
Active Features
Braking System:
Front: Ventilated Disc, Rear: Drum
Parking Brake:
Mechanical, rear drum
Passive Features
Seatbelts:
Standard front seatbelts (likely 2-point or 3-point depending on market)
Body Construction:
Monocoque chassis with integrated safety cage elements
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, optional cassette player
Driver Assistance
ABS:
Not available
Connectivity
Connectivity Features:
None (analog systems)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km or 6 months, whichever comes first
Oil Filter Replacement:
With every oil change
Air Filter Cleaning Or Replacement:
Every 10,000 km or 12 months
Spark Plug Replacement:
Every 20,000 km or 24 months (use NGK BP6ES or equivalent)
Coolant Flush And Replace:
Every 24,000 km or 24 months
Fluid Specifications
Engine Oil Grade:
API SF/SG, SAE 10W-30 or 10W-40 (ambient temperature dependent)
Engine Oil Capacity Liters:
Approx. 3.0 liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze/coolant, mixed 50/50 with distilled water
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Rust Prone Areas:
Wheel arches, sills, floor pans, door bottoms (common for vehicles of this age and construction)
Carburetor Issues:
Clogged jets, worn diaphragms, vacuum leaks leading to rough idling or poor performance
Ignition System Reliability:
Points and condenser wear, coil failure, distributor issues
Suspension Wear:
Worn bushings, ball joints, and shock absorbers leading to clunks and poor handling
Electrical Corrosion:
Corrosion in connectors, grounds, and fuse box, especially in humid climates
📚 Vehicle History
Brand Heritage
Founding Principles:
Suzuki has a long history of manufacturing small, economical vehicles and motorcycles, emphasizing innovation and affordability.
Model Evolution
Predecessor:
Suzuki Fronte (various generations)
Successor:
Suzuki Alto (SS80/SS11)
Design Intent:
To offer a more stylish and slightly larger alternative to the traditional Kei car segment, suitable for everyday commuting and light family use.
Production
Production Period:
1977-1982
Manufacturing Locations:
Japan (Hamamatsu, Shizuoka)
🏆 Awards & Recognition
Recognitions
Market Reputation:
Recognized for its fuel efficiency and low running costs in its segment.
Ratings
Fuel Economy Km L:
Approximately 18-22 km/l (50-62 mpg US) depending on driving conditions and transmission.
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