Suzuki Alto 1977-1984 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: Alto Model Generation: First Generation (SS30/SS40) Production Years: 1979-1984 Codes Chassis Codes: SS30, SS40 👋 Introduction Market Position Target Audience: Professional technicians and DIY mechanics with adequate experience Competitive Analysis Value Proposition: Provides comprehensive factory-level repair information for cost-effective maintenance and repair, enabling users to make informed decisions. Key Features Features: Step-by-step procedures, high-quality diagrams and illustrations, exploded views, critical specifications, troubleshooting guides, complete coverage of all styles. Usability Ease Of Use: Easy-to-read text sections, clear instructions, detailed pictures and diagrams 📋 Manual Details Coverage Areas Countries Of Sale: Global (with regional variations) Page Count Estimated Page Count: Hundreds of pages (exact count not specified, but described as 'complete' and 'hundreds of pages') Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system Drivetrain: Clutch, transmission (manual and automatic), drive shafts, differentials Chassis: Suspension (front and rear), steering system, braking system, wheels and tires Electrical: Ignition, starting, charging system, lighting system, instrumentation, wiring diagrams, body electrical Body: Body panels, interior trim, doors, windows, seats, bumpers Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Troubleshooting: Diagnostic procedures, symptom analysis, common fault diagnosis Repair: Step-by-step repair instructions for all major components and systems Disassembly Assembly: Detailed instructions for component removal, disassembly, cleaning, inspection, reassembly, and installation Technical Data: Specifications, torque values, tolerances, clearances, diagnostic data Technical Depth Depth: Comprehensive (suitable for professional technicians and advanced DIY mechanics), covers complete disassembly and rebuilds 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full Printable Zoom Functionality: Yes (Zoom IN/OUT) Binding Type Binding Type: Digital Download (no physical binding) Paper Type Paper Type: N/A (Digital PDF) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Codes: F5A (543cc), F5B (797cc) Performance Horsepower Range: Approx. 25-37 PS (depending on engine variant) Torque Range: Approx. 37-50 Nm (depending on engine variant) Fuel System Carburetion: Single-barrel carburetor (e.g., Hitachi) for most variants Cooling System Cooling Type: Water-cooled Lubrication Oil Type Recommendation: Refer to manual for specific API service classification and viscosity grade (e.g., SAE 10W-30 or 10W-40 depending on climate) Engine Layout Configuration: Inline 3-cylinder, SOHC (Single Overhead Camshaft) 🔧 Transmission Standard Transmission Type Standard: 4-speed manual Optional Transmission Type Optional: 3-speed automatic (less common) Features Clutch Type: Dry single plate Fluid Specifications Manual Transmission Fluid: Refer to manual for specific GL rating and viscosity (e.g., GL-4, SAE 75W-90 or 80W-90) Automatic Transmission Fluid: Dexron II (or equivalent) 📐 Dimensions Exterior Length: Approx. 3,195 mm (125.8 in) Width: Approx. 1,395 mm (55.0 in) Height: Approx. 1,380 mm (54.3 in) Weights Curb Weight: Approx. 560-650 kg (1235-1433 lbs) depending on configuration Wheelbase Wheelbase: Approx. 2,065 mm (81.3 in) 🛡️ Safety Features Ratings Crash Test Information: Limited modern crash test data available due to era; emphasis on basic structural integrity and occupant protection typical of early 1980s vehicles. Active Features Braking System: Front disc brakes, Rear drum brakes Passive Features Seatbelts: Standard front seat belts 💡 Technology Features Infotainment Audio System: Basic AM/FM radio, often with a single speaker. Cassette player was an option on higher trims. Driver Assistance Assistance Features: None (vehicle predates modern driver assistance systems) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first (refer to manual for precise interval based on driving conditions). Air Filter Replacement: Every 10,000-15,000 km (6,000-9,000 miles) or annually. Spark Plug Replacement: Every 20,000-30,000 km (12,000-18,000 miles), or as per manual specifications. Timing Belt Replacement: Crucial procedure. Typically every 60,000-80,000 km (37,000-50,000 miles) or 4-5 years. Failure can cause severe engine damage. Fluid Specifications Coolant Type: Ethylene Glycol based antifreeze, mixed with distilled water (50/50 ratio). Refer to manual for specific OAT/HOAT requirements if applicable. Brake Fluid Type: DOT 3 or DOT 4. Known Issues Common Wear Items: Ignition components (points, condenser, coil), carburetor issues (gumming, wear), suspension bushings, exhaust system corrosion, clutch wear, door lock mechanisms, rust (especially in door sills, wheel arches). Electrical Gremlins: Wiring harness degradation, connection corrosion, grounding issues can lead to intermittent electrical faults. Technical Tips Carburetor Adjustment: Regular cleaning and adjustment of the carburetor is often necessary to maintain optimal fuel-air mixture and performance. 📚 Vehicle History Brand Heritage Suzuki Automotive History: Suzuki Motor Corporation, a Japanese multinational company, has a long history in motorcycle and automotive manufacturing, known for its small, efficient, and economical vehicles. Model Evolution Alto First Generation Introduction: The first generation Alto (SS30/SS40) was introduced in 1979 as a kei car, designed for Japan's domestic market with compact dimensions and engine displacement restrictions. It was known for its fuel efficiency...
Refer to manual for specific GL rating and viscosity (e.g., GL-4, SAE 75W-90 or 80W-90)
Automatic Transmission Fluid:
Dexron II (or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 3,195 mm (125.8 in)
Width:
Approx. 1,395 mm (55.0 in)
Height:
Approx. 1,380 mm (54.3 in)
Weights
Curb Weight:
Approx. 560-650 kg (1235-1433 lbs) depending on configuration
Wheelbase
Wheelbase:
Approx. 2,065 mm (81.3 in)
🛡️ Safety Features
Ratings
Crash Test Information:
Limited modern crash test data available due to era; emphasis on basic structural integrity and occupant protection typical of early 1980s vehicles.
Active Features
Braking System:
Front disc brakes, Rear drum brakes
Passive Features
Seatbelts:
Standard front seat belts
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, often with a single speaker. Cassette player was an option on higher trims.
Driver Assistance
Assistance Features:
None (vehicle predates modern driver assistance systems)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first (refer to manual for precise interval based on driving conditions).
Air Filter Replacement:
Every 10,000-15,000 km (6,000-9,000 miles) or annually.
Spark Plug Replacement:
Every 20,000-30,000 km (12,000-18,000 miles), or as per manual specifications.
Timing Belt Replacement:
Crucial procedure. Typically every 60,000-80,000 km (37,000-50,000 miles) or 4-5 years. Failure can cause severe engine damage.
Fluid Specifications
Coolant Type:
Ethylene Glycol based antifreeze, mixed with distilled water (50/50 ratio). Refer to manual for specific OAT/HOAT requirements if applicable.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Wear Items:
Ignition components (points, condenser, coil), carburetor issues (gumming, wear), suspension bushings, exhaust system corrosion, clutch wear, door lock mechanisms, rust (especially in door sills, wheel arches).
Electrical Gremlins:
Wiring harness degradation, connection corrosion, grounding issues can lead to intermittent electrical faults.
Technical Tips
Carburetor Adjustment:
Regular cleaning and adjustment of the carburetor is often necessary to maintain optimal fuel-air mixture and performance.
📚 Vehicle History
Brand Heritage
Suzuki Automotive History:
Suzuki Motor Corporation, a Japanese multinational company, has a long history in motorcycle and automotive manufacturing, known for its small, efficient, and economical vehicles.
Model Evolution
Alto First Generation Introduction:
The first generation Alto (SS30/SS40) was introduced in 1979 as a kei car, designed for Japan's domestic market with compact dimensions and engine displacement restrictions. It was known for its fuel efficiency and affordability.
Production
Manufacturing Locations:
Primarily Japan (Kosai Plant)
Model Variants
Engine Options Availability:
Initially with a 543cc engine, later expanded to include a 797cc engine for export markets.
🏆 Awards & Recognition
Recognitions
Kei Car Segment Accolades:
While specific awards for the 1977-1984 Alto might not be widely documented in English-language automotive press, its consistent popularity and sales success in the Kei car segment in Japan reflect its effectiveness and market acceptance.
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