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...