Daihatsu Midget II SM 1996 Jpen

Machine Translated by Google
Introduction
This document describes inspection and maintenance procedures for vehicles released in April 1996 . Accurate and accurate inspection and preparation
Please make full use of this manual so that you can work quickly.
Please note that the items described may differ from the vehicle due to subsequent changes.
June 1996 _
Reference material
capital fee Name Document code Publication date
Midget 1I Service Manual Commentary No. 1 EKOllA March 1996 _
wa ' !.()\' Li Industry Co., Ltd. Domestic Service Department

1111 table of contents 1111

A Review 1 How to read the maintenance l Removal and installation of seals ---- ---- ---- ---- ---- ---- ---- ----
section•…………………………ÿÿ[ Saio] 1- 1 How to read the --- --- --- --- 3 Cam, valve mechanism ------------ --------- ÿ1. Ward pressure]
maintenance section••••••••••••••••-------• Mouth ÿ Mouth 2 3- 1 Timing belt removal and installation

units ------------------------------------ ------ ÿÿÿ ÿYesÿ 3 Tightening -------------------------------------------------- -Comparable King
Torque•-------------------------------- --[§W] 3- 1 Tightening torque 3-2 Remove the camshaft oil seal ,
for general standard bolts and nuts INSTALLATION --- …………-----------•----•----- SECTION
Grasping point ----------------------------------- ÿÿ [No] 4 3- 3 PREPARATION ---- PREPARATION ---

Symbols used Meaning of abbreviations · --------------------- ----------------------------Kyoto Ward] 3 -4 Removal and
ÿÿÿSayoÿ 5 Precautions for general work …………………… installation of the camshaft--Wataru Todo] 3-5 Remove valve stem oil s
ÿSaioÿ 6 Jack P•1…………………… Mouth and ÿ] 4. Lubricating device —------------ ---------------------- ÿÿ

7 Lift support points and rigid rack supports ÿÿWest District] 4-1 Removing and installing the oil
Possession ………………………………… ÿ [Reciprocal] pump ------------- --------------------------------------- 4-2 Oil
B Inspection and maintenance pump disassembly and assembly _______________
I 1 Periodic inspection and maintenance method ------------------------- - 4-3 Oil pan removal and installation ... 4-4 Oil pressure
--- [Masao] | c. engine test _______________ _______________ 5 Cooling

I 1 engine adjustment ---------------------------------- IT ] 1 -1 system ---- --•----- Sanjo Ward]
Preparations ---- ----------------------------------- Mouth 1-2
Cooling water level check —----- ---------------------- ÿÿÿ B 5- 1 Thermostat removal and installation
1- 3 Checking the function of the radiator ------------ÿÿ --------------------. --------. ------------------.- - @:ill
-Big ÿ 1-4 Jeter Cap & Water 5-2 Removal and installation of water pump
Function check of the valve-------------------------- ------------------------------------------- — Ver. 5- 3 Radiator
1-5 Cooling water injection procedure (notes for maintenance of cooling system removal and installation … Section 5-4 Radiator fan
water) ---------------------------------------------------- ] 1- 6 inspection —----------______ Section] 6 Air intake and
Cooling water specifications ---------•---------------------• exhaust equipment ---------- ------------------------- ward huge pressure]
Available ] 1- 7 Engine oil amount check --------------- 6- 1 Intake manifold gasket
mouth [ 1-8 Spark plug check --------- low [] 1- 9 Removal and installation -------------------- …
Alternator belt tension (deflection) 6-2 Exhaust manifold gasket
inspection and adjustment ------------------------------------ [ Removal and installation ]

Turf [ 1-10 Check valve clearance ...- --------- 1- 11 6- 3 Exhaust pipe removal and installation
Compression pressure check ----------------------- Section ---------------------------------------------------- E Tama ÿ 7
100 1- 12 Ignition Timing check, adjustment Engine Ay-------------------------------- ____-- Kuyumikai] 7
-1 Remove Engine Ay , Mounting…… Section 8 ] -
-------------------- 1-13 Idle rotation speed check, adjustment ----------
1-14 Idle CO and HC concentration check and 1Remove and install fuel tank Remove and install pump
adjustment --------------------------------------- ---------—One word ----------------------------- -----------
1-15 Throttle positioner inspection and adjustment ---------- -·- ------------------ -------------------
-----------------------------------------------------ÿCategory 2 8- 2 fuel
power unit. . . . . . . . . . . . . _. . . . . . . . . . . . . . _. . . . .ÿ•…
Yumigo] 2- 1 Remove the cylinder head gasket 8 -3 Remove the fuel filter
and install. . . . . . 1 ••• 1-•••------------ 1. ---Ku Hyakuoh 8- _ _ 4Removal and installation of the caplet _--
—
l 2-2 Piston removal and installation --------Ku Yuuo] large pressure] 9Exhaust gas purification device
2 -3 Crankshaft front oil ------------------------

9-1 Exhaust gas purification equipment list 1 •• • •• 2-5 Remove backup lamp switch Ay
— ----- … 9-2 Exhaust gas purification system and install -------- ----......------- Remove
diagram ……… 9-3 Exhaust gas recirculation 2-6 Transmission Floor ShiftAy
Device ---..--------- 9-4 Ignition timing control device REMOVAL AND INSTALLATION ----••---------------
-------------. ...-- [Mutual West] 9-5 Deceleration 2-7 shift cable Ay & select cable
control device. . . 9-6 Auxiliary control device Pull Ay removal and installation -------
-------
— ÿÿ ]
----------... .--------••• Ku Luo] 9-7 Evaporative 2-8 Transmission Floor ShiftAy
emission control device. . . . . . . . . … Ward: West] Disassembly and assembly •-••-.....-••-•--•---•-------- ÿ
10 Ignition device. . . . . . . . . . . . . . . Category---..------ Problem] 3 Propeller shaftÿÿÿÿ ------ -•---•----------• Mouth-to-mouth]
… Sanxi District] 1 0-1 Preparations ------ 3 -1 Removal and installation of propeller shaft
_........ ......_.................. 1 0-2 system diagram•-••------ -----------------------....-------------- 4-1 Rear differential

ÿÿ . . . . . . . . . . . . . . . . --- Section Bow 1 0-3 Ignition removal, removal
Coil ---•---..-- Section Bow 1 0-4 Ignition Plug 1
-----... ....._...........Gu Beans [ 1 0-5 Distributor . . . . Attachment•-••-••••-••-•••--•---------•••---------••-- ÿWataÿ
_. . . . . . . . —- Ku Yuryo] 11 Starter. . . . . . . . . 1•••••• 4-2 Rear differential disassembly and assembly
-----• --• • • • • • • • • • • - -----• · · · · • -- -----• -• · • ---•
—------------------- 3:00pm] 11 -1Preparation / Mingo

5 Axle …------•---------• •--•--••- ·
0... ....----........---1 Section 11 -2 System Nishi]
5-1 Removal
Diagram--------........_. ...... …… Section 11 -3 Starter and installation of rear axle
12 Charger---•---.. —
removal and installation . --

-- -------- --- - • • • ---- --- • - • • -- -------- • ----- • •
Country
1 2-1 Preparations -------------••Ward: West] 11 -4 2Remove rear axle housing Ay 5-
Check. . . . . . . . . . _. . . . . . . . . . . . . . ••--- — -. . . . . and then attach ------------------------------- Bend]
--- Ward Yuuo] ...-••---------------···· … Ward Yusei] •---lE. Chassis ---- - --| 1 Engine -mounting·—--
••-••--- -------• Ward Kyosho] 1 2-2 System diagram ----- . 1 2-3 On-board inspection •ÿÿ •—••--•-••----•_... ---•----- Zone pressu
.................. ÿ •ÿÿ . . . . . . . . . . . . . . .....ÿ•Lyricsÿ 1 -1 Engine mounting removal, removal
D Drive I 1 Clutch --------------------------------------- ÿ Exit 1 Attachment …------------------------ ---- --- ---- ---------
-1 Clutch pedal adjustment --- --------------- Kuchikyoo] 2 Suspension ------ — --------- [Shinno] 2-1 Wheel
Alignment -------------- [Countryÿ]
1-2Cluster pedal removal and installation 2-2 Front shock absorber removal
-------------------------------------------------- ---- country Remove , Install --- — ---- --------------- ----- [Giant]
1-3 Removal and installation of the clasp cable 2-3 Suspension lower arm & stabilizer
-------------------------------------------------- 1 -4 Clutch Removal and installation of the riser bar …Masahiro]

installation/removal -------- ÿE[ 2Manual 2-4 Remove the rear shock absorber ,
transmission -------- ÿE[ Mounting ----------------------------------

2-1 manual transmission identification 2-5 Remove the rear leaf spring
-- ----------- ---------• • • • • • • • • • • • • • • • • • • • ----------- One word Mounting -------------------------- _ … … ----
2-2 Manual transmission removal
and install ------------- ------------------- 3 -1 Steering wheel (two- spoke
2-3 Extension housing oil Made of resin) Removal and installation …………Masa Wataru]
Removal and installation of seal -------- 3 -2 Remove and remove the steering
2-4 speedometer driven gear removal Attachment ---------- — column Ay --------------------- ----------
Removal and installation --------------------- - 3 Disassembly and assembly of steering column Ay
ÿ 1111 table of contents 1111ÿ

hair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ································ 4-3 Important points for removal - 1 ••—•••-•--•-•--
3-4 Manual steering gear removal •-•-•-••-- 4-4 Important points for installation...--•-
Remove and install. . . . . . . . . . . . . . . . . . . . . . . . . . . . --Kazuro installation 5 Bumper- &

•••bumper
--•--•---•- ] 4-5 Work after
3-5 manual steering gear Ay minutes guard•-------------------------------------- 5 -1 Work before
Solution, assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . removal-- 5-2 Removal and installation
Wataru Masaro] 4 Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . procedures ------------ 5-3 Post- installation work
—• Continue 4-1 Brake inspection, tuning. . . . . . . . . . . . . . . . . . . …… 5-3 - Dimension mutual ox mutual l
--- 4-2 pedal brackets and brake pedals 6 Tilt & Tilt Resin Panel & Roll Bar
Remove and install dull. . . . . . . . . . . . . . . . — Allowed to bow ------------------------------------------------ one
[Lyrics ]
4-3 Remove brake master cylinder 6-1 take Removal and Installation Procedures 7
and install. . . . . . . . . . . . One •••—------. . . . . . . . . [Minister] Side Skirts & Rear Skirts — 7-1 Removal and
4-4 brake master cylinder disassembly, Installation Procedures ----- ••----•---R Circle I] 8
Assembling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Instrument panel • _. . . . . —•••---•--•Masame ÿ] 8-1
Karuroguchi 4-5 Brake booster operation check ÿ . — ••• Wataru Work before removal •--•-•--••-••--•--•-•-••--•Masame
Masami] 4-6 Removal and installation of the brake booster 8-2 Removal and installation procedure. . . .ÿ
ke--------------------------------------------------------------------- yo times •••••ÿ---Mass yo l 9 sheets ················
4-7 Brake booster disassembly and assembly ··········································· _ _ . . . . . .
---------------------------------------------------------------------- ·lord ---------------------------------- 10 times -1 Removal and
4-8Remove the front brake drum, installation procedure •--•-.....-• 10-2 Important
attachment. . . . . . . . . . . . . . . . . . =. . . . . . . . . . . . . . . . . . — Kasakyu blade points for removal
4-9 Remove the rear brake drum
Add. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swallow each other]
4-10Remove and remove the parking brake

Add. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ···························································································································································································· . 10-3 Inspection o
Speech ] Nation Nation Yo 1 building adjustment •----..-- _........_..---
[Giant King] 1- 1 Around the front panel•ÿÿ••••ÿ••••ÿ•ÿ•[Large i] One lamp

11-2 relationship
Installation ----------------. . . . . ÿ ''i
points——••-•---•-••-•--••-
1-2 Around the front door•Category•• ÿÿÿÿÿÿÿÿÿÿÿÿÿÿ•ÿÿ[Takumi Large ÿ 1-1 Head lamp ------------------------ Section 2
Mutual] 1-3 around the side of the deck ----- Combination meter ----- ---•-•-- ÿE] 2-1 Removal
·······································[Kyo] Around the rear of the 1-4 deck · ÿ and installation •-•--•--......---•-- 2-2 Circuit diagram
ÿ. . _. . . . _. . 1 •• ÿÿÿÿÿÿÿÿ .. ÿ ÿÿ 1-5 Bumper guard & roll bar ························· _ _ . . . . . —•------•----•-- Mizo [ 3
---- [E bow] 2 Front door --------- ••---•--••-••••••• 2-1 Trim, glass, fuel gauge & water temperature warning light. . . . . . .
lock — Big E ] 3-1 Fuel Gauge --- • • ------------ ÿE
Mutually 3-2 Flood Switch ----- --••-......_...--.....-·
1 •• 1 •• 8 Front panel center cover 3-1 Removal Mr . . . . . . . . . . . . . . —··························
and installation procedure .....ÿ••• 1ÿ•ÿ{Mutual
Three ÿ 3-2 Points of installation......Category••--
••--...-.....--• [E ox] 3-3 Work after installation•ÿ•ÿ• 4-1Forgetting to remove the key warning buzzer function
ÿÿ . .ÿÿÿ••••ÿÿ. --•--- Mouth big round] 4 side .................................................. ·@±J 5
panel ................_....--• ÿÿcategory• -- 4-1 Pre- wiper•----------------------------- 1 front wiper
removal work .................. 4-2 Removal and -------------------
installation procedures ..-- . yo l

1 Maintenance standard value ÿ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [Watou]
1-1 engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [Watou]
1-2 drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ÿ E Engineering]
1-3 chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . {Watari yo}

How to read maintenance
1 How to read maintenance

1-1 How to read maintenance
1-1-1 Prepared items
If you need SST, tools, instruments, oils and fats, etc. that should be prepared in advance for work, prepare items and
are summarized in the table.
However, general tools, jacks, fixtures, etc., which are considered to be always available in maintenance shops, are usually omitted.
increase.
1-1-2 Removal and installation (disassembly and assembly) procedures

1. The numbers in the component parts diagram indicate the removal (disassembly) procedure. The installation (assembly) procedure is basically
This is the reverse procedure of removal (disassembly).
(Reference) Installation (assembly) is only possible for metal fittings that cannot be installed (assembled) in the reverse order of removal (disassembly).
We have procedures.
2. Add markings (ÿ, ÿ) in front of the part name when special instructions are required for the work,
It is explained in the section "Points of Solution)" and "Points of Installation (Assembly)". ÿ has the point of installation (assembly)
indicates that
3. In the component parts drawing, arrows indicate the application of oil, sealant, etc. Also, tightening torque and non-reusable
Available parts are also listed.
lT:31~411320~420fÿ
ÿ
*
ÿ
Unit: N•mlkg•cmf
*: Non-reusable parts
ÿBolt
ÿ Caliber Ay, disc brake
,,.....ÿPress the clip pin
,,.....ÿPin with hole
®Pad Ay
ÿ...® Shim
SKISIOOI
A-1
How to read maintenance
1-1-3 Content omitted in this document

Although the description of the following elemental work may be omitted in this manual, please perform it in the actual work.
1. Jacking and lifting operations
2. Clean and wash detached parts as required
3. Visual inspection
1-1-4 Definition of terms
Represents the allowable range of values for humidity inspection and adjustment.
Indicates the maximum or minimum value that should not be exceeded during dust inspection and adjustment.
Since it is difficult to determine the standard value by the measurement method, the standard value in the simplified measurement method is used when there is no practical risk of failure.
(reference)
represents
ÿ: A value that represents the difference between the maximum clearance and the minimum clearance.
Troubleshooting] Items to be particularly noted and prohibited items are specified in the work instructions.
Items that may lead to personal injury are described in E-snow work guidelines.
SKISIOI
2 credits
Units are described in the SI (International System of Units) Level 2 notation (SI units and conventional units are listed together).
Example: 33.25 ft 13.25 N m {340 ft 135 kg cm}
1. New units due to the introduction of SI units
With the introduction of SI units, typical conventional units will change as follows.
Item new unit Conventional unit conversion value Item new unit Conventional unit Converted value
N
Power kgf lkgf=9. 80665N Spring constant N/m kgf/mm lkgf/mm=9.80665N/m
(Newton)
Nm Pa kgf/cni lkgf/ai=98.0665kPa
g) Rec kgf cm lkgf cm= 0.0980665N m Pressure
(Newtsome) (Pascal) 111111Hg l dish Hg=O.133322kPa
SK1S102
2. SI Prefix
Typical prefixes for SI units (lo to the nth power) are as follows.
M (Mega) 106 d (deci) 10-1=0.1
k (Kilo) h 103 c 10-2=0.01
(Hect) 102 (centimeter) 10-3=0.001
da (deca) 101 m (millimeter) µ (micro) 10-6=0. 000001

SKISI03
A-2
tightening torque
3Tightening torque
3-1 Grasping torque for general standard bolts and nuts
3-1-1 How to Grasp the Tightening Torque of Bolts
Determine the strength class of the bolt from the table below, and find the value from the tightening torque table.
3-1-2 How to grasp the tightening torque of nuts

The mating bolt is grasped by the method described above.
.. .
3-1-3 identification
Identification of strength class by actual product Identification by part number
Type Head shape (How to read the strength classification)

1 Hex bolt I
(strength class) collarless bolt flat bolt
Part number example 9 1 1 1 1 -4 0 6 2 0
.
B call: : (ko?sa (mm)
4T _
Strength class
Nominal diameter around

G '|
5T _ Under neck length
6T _
7T _
.
3-1-4 General standard bolt tightening torque table
SK1S104
(mm)
Nominal pitch Standard tightening torque (N • m { kg • cm })
Strength class
diameter (mm)
collarless bolt flanged bolt
6 1.0 5.4 {55} 5.9 {60}
8 1.25 13 {130} 14 {145}
10 1.25 25 {260} 28 {290}
4T _
12 1.25 47 {480} 53 {540}
I
14 1.5 74 {760} 83 {850}
16 1.5 113 {1150}
6 1.0 6.4 {65} 16
8 1.25 {160} 32
10 1.25 {330} 59
5T _
12 1.25 {600} 91
14 1.5 {930} 137
16 1.5 {1400} 7.8
6 1.0 { 80} 19 {195} 8.8 {90}
8 1.25 39 {400} 72 20.5 {210} 43
6T _ 10 1.25 {730} 109 {440} 79
12 1.25 {1100} 11 {810} 123
14 1.5 {110} 25 {1250} 12
6 1.0 {260} 52 {120} 28
8 1.25 {530} 9.5 {290} 58
10 1.25 {970} 147 {590} 103
7T _
12 1.25 {1500} 225 {1050} 167
14 1.5 {2300} {1700}
16 1.5
SK1S105
A-3
Meaning of symbols and abbreviations used
4 Meaning of Symbols Used

The following symbols are used in this manual.
symbol original language intention taste
RH Right Hand _ right side

LH Left Hand _ left side
FR Front (front) Previous
RR Rear (rear) rear
In the sense of standard, the component sizes used when assembled by the manufacturer are
STD Standard _ Show standard.
For items that have worn out due to long-term use, or that have become loose due to repeated attachment/detachment,
0/S Over Size By exchanging the fitting side (e.g. piston) with one of larger size, the mating side
can be reused. Those with dimensions larger than this STD are displayed as 0/S.
As in the case of 0/S, place a small hole on the side to be fitted (bush, bearing, etc.)
By exchanging with U/S Under Size , the other side (shaft) can be reused. this
The size smaller than STD is indicated by U/S.
Stringer Top Dead

ATDC After piston top dead center in cylinder
Center _
Before Top Dead Center

BTDC Before top dead center of piston in cylinder
__
IN Intake _ Represents the intake system.
EX Exhaust Represents the exhaust system.
Society of Automotive Engineers It is this SAE number that refers to CC retention when referring to oils. this is america
SAE ( Society of Automobile Engineers Association (abbreviated as SAE)) stipulates that the higher the number, the higher the viscosity.
engineer) The higher the value, the lower the viscosity.
American Petroleum Institute standards (abbreviated as

American Petroleum Institute
API service classification) is used.
API (American Petroleum Institute)
For gasoline engines, SD, SE, SF, etc. For diesel engines, CC,
There are classifications such as CDs.
Special Service Tool

SST __
Special tool
T Torque _ tightening torque
Combine two or more single parts or sub-assembly parts to form an assembly.

Ay Assembly _
parts
Sub Assembly
S/A Parts in which two or more single parts are joined by welding, caulking, etc.
WI With (With) It comes with the following: (Example w/washer...with washer)

Ply Rating
PR It represents the strength of the tire, and the higher the number, the stronger it is.
__
Manual Transmission
M/T manual transmission
_
Automatic Transmission
A/T automatic transmission
___
Turbo Charger
TIC supercharger
ÿ Bolt® (bolt)
Screw _ ( Screw ) When expressing standard bolts, screws , nuts, and washers by omitting them in drawings
(Nut) Symbol
Nut® Washer _ (washer)
SKISI06
A-4
General precautions
5 Precautions for general

work 1. Jazz up and lift up
(1) When jacking up only the front, rear, and rear of the vehicle, be sure to chock the wheels for safe work. (2) When
jacking up the vehicle, be sure to support the specified points with rigid racks ( wheel stands ). (3) When lifting the vehicle, be
sure to set the pedestal for the lift at the specified location before lifting.
Also, after lifting, be sure to engage the safety device.
2. When repairing the electrical system or removing or installing the engine, disconnect the negative terminal of the battery before starting work.
(For a car equipped with a clock, set the clock after connecting the negative terminal
of the battery .) 3. Repairing the fuel system Pay attention to the following points because the
fuel injection engine has high fuel pressure. (1) When removing the union bolt, loosen it
gradually while using a waste cloth or the like to prevent the fuel from scattering.
get
(2) Tighten each connection part to the specified
torque. (3) Attach a specified clip to each joint.
4. Effectively utilize SST (special tools) to improve work efficiency and accuracy . 5. Removal and
disassembly
(1) For complicated parts, in order to make the assembly work easier, put stamps, alignment marks , etc. on places that do not affect the function.
be.
(2) Each time a part is removed, inspect the assembled state, deformation, damage, roughness, scratches, etc.
(3) Arrange the removed parts in order and separate the parts to be replaced from the parts to be reused. (4)
Each part to be reused should be thoroughly cleaned and washed. (5) Inspection and measurement of parts
Parts to be reused shall be inspected and measured in detail as necessary.

6. Mounting and assembling
(1) Assemble good parts in accordance with the specified standards (matching values, tightening torque, etc.) in
the correct procedure. (2) When replacing parts, use genuine parts. (3) Do not forget to apply seal packing or grease
depending on the location . (4) Always use new pads, gaskets, cotter pins, etc. (5) When using a seal bolt, apply the
specified liquid gasket and seal lock agent. (6) Use specified bolts and nuts. Unless otherwise specified, use a
torque wrench to tighten the side with the torque display to the specified torque, and the other side has no anti-rotation device. ,
use goggles, spanners, etc. to securely stop the rotation. 7. Adjust to the specified maintenance standard value using adjustment,
work confirmation gauge, and tester. 8. Handling of hoses
(1) Remove fuel hoses and water hoses and insert them securely to prevent leakage. (2) When removing the
fuel hose, do so that it will not be exposed to fuel. (Engine mount rubber etc.
Pay particular attention to phosphorus-based liquids, as the materials may
deteriorate .) 9. Touch-up Scratches on the coated surfaces of the body and bolts when the
bolts are removed during body installation, etc. is corrected by body color.
A-5
jack up
6 Jack up
0 Jack-up support point

Front side… Front suspension member central protrusion
Rear side•••Rear differential
Rear side…Rear differential
SKISI002
A-6
Lift Support Points and Rigid Rack Support Points
7 Lift Support Points and Rigid Rack Support Points
Lift Support point

• Swing arm type
Front side•••Diagram below
(Support points are spot-welded with reinforcing plates. , Since the strength is increased,
Do not hold the vehicle. )
Front
Rear side … Leaf spring bracket
Rigid track Support point

Front side…same location as the swing arm front side in the figure above
Rear side… Rear axle
SK!S1003
A-7
Regular maintenance method
1 Regular maintenance method

1. The “•” marks indicate inspection times required by law.
2. The "ÿ" mark indicates the severe condition, and the "ÿ" mark indicates the distance item.
3. ÿ indicates the item described in the instruction manual, and ÿ indicates the item described in the maintenance note.
, ÿ, ÿ ;, Inspection and maintenance timing notification method
,ÿ•ÿÿ i. Inspection and maintenance items for , r, . ,,, Judgment

preparation
Miko, J. 's Judge ,. _ J Yojun remarks

Real H 6 12 24
.
, I,1.i , 9 width perspiration All
point, check term H direction
part '9' (-) or 9 ' strength
node
n ru operation condition
GyaBock
nine
Loose mounting ÿÿ
Power'
A looseness , backlash and damage ÿ
character
Ball joint dust

ÿÿ
Cracks and damage to Tsukimata boots
in the shadows
Toe-in - lmm ~ + 3mm

;I , I:
wheel alignment ÿ camber . ÿ10' Sat 45'
.. .
Caster 7 ° 15'
Ri :
,, , loosened and damaged dovetail

belt
; Oil leak and oil wipe
Motorized type does not require inspection
outfit
the 7
;rt Loose mounting ÿ
play 2~8mm
pu Gap rH'J
. . . ÿ ÿ When stepped on with a pedaling force of 30kg
Les
Gap between floorboard and 43mm or more
tree Braking force
bae
How the brake works . . . ÿ ÿ 10% or more of I rear wheel total shaft
Da 1 Difference between left and right 8% or less of straight axis
system } 50 for vehicle heavy wiping during inspection

Total sum
% less than I.
Operation) At J 20 ratio
Agony / [
withdraw . . . ÿ ÿ Pull margin 1~5 notches
dynamic
..
Full stroke 12 notches
ÿ
Braking condition Braking force 20% or more of vehicle weight at inspection
B Ke
stay
ÿ ÿ
[ Looseness , looseness and damage
. ..
Ho
, Pizu
I
Leakage, damage and installation condition . . .
ÿÿ
liquid level
liquid envelope ÿÿ
flat ULKu
ox} Must be between MAX and MIN
Li
hmm
vinegar'
.
Da I liquid leak
and Better
0 19
ah
I da
vinegar 1
nine
function, wear and tear

) Les
Pajeong
1 Si
B-1
Inspection/maintenance timing Notification method
, inspection and maintenance items

preparation
Vehicle inspection
Miko Top ÿ Base
judgment , judgment remarks
Day 6 12 24 fruit
base
Inspection items potmonth
strength
month month
direction
Inspection points
every inspection every law
gap between drum and lining ÿÿ

Le Le
Standard thickness Front wheel 5mm Rear wheel 4mm

ÿ ÿ Sliding part of shoe and line ÿÿÿ disc brake
do
cleaning wear Use limit Front wheel 1mm Rear wheel 1mm
shiyu does not require inspection
centre
system
ml Standard diameter front wheel 1 80mm rear wheel 180mm

Drum wear and damage ÿÿ
Excited Use limit Front wheel 181mm Rear wheel 181mm
outfit Clearance between disc and pad ÿÿ

Push
rear wheel mm Front wheel Use limit
mmBoth
Standard
frontthickness
and rearof
ÿÿÿ Drum brakes do not
Wear of hill pad wheels mm
require inspection
i
tsu Standard thickness Front wheel mm Rear
.
Disc wear and damage ÿÿ
wheel mm Use limit Front wheel mm Rear wheel mm
Air pressure (unit: kg /cm')

tire pressure ÿ I Tire size I Front wheel I Rear wheel | I
145/95 RlO I 9 | 2.2 I 1 .
Run Ho
Tire cracks and damage . ÿÿ
Tire tread depth and uneven

row i . . . ÿ ÿ Remaining groove up to 1.6mm
wear
Wheel nut and wheel Wheel nut tightening torque

outfit _ ÿÿ
Loosening of the ball bolt 9~ 12kg•m
Backlash of front wheel Axial play at center of axle

four. ) Le ÿ
bearing 0~0.05mm
rear wheel bearing Axial play at center of axle

ÿ
Nogata 0 . 1~O.Smm 2WD
.
takingBeauty
Loose Looseness, backlash and damage ÿÿ

shoes
Agony
Si
jeop , no
Along
phantom
Oil leak and damage
ah l
When dynamic multi- pedal play and break

force ; crevices with floorboards
.. Yupi 15~ 25mm Automatic
20mm or more clearance with the stopper when broken No inspection required for vehicles
..
Tradition
reached
Between 0 to 5 mm from the lower surface of the filler plug hole
;
Pu: Oil leaks and oil leaks
n to be in
F
"ii.
njoa 1
pro
Integrated joint type
Loose connection ÿÿ
;
No inspection required
rad fallacy
n, `/,
ya
yahu Dustboo of the Freedom of Relations Department
Bok
ÿ•
cracks and damage
Lu §
Fudecine Between 0 and 5mm from the lower surface of the filler plug hole
a ya Oil leak and oil wipe ÿ
Rel there is
Plug Cap 0.7~0.8mm * 1
..
Frost I'', b, 9 ÿ
Platinum plug or
Air Fire : 0.9~1.0mm * 2
spark plug condition de easel car
Clothing I. I: Clothing * 1 W1 6EXR-U , BPR5ES
"four" housing
* 2 Wl6DTR-S , BPR5EK-B
B-2
J,'.i_Method of informing inspection/maintenance timing
Inspection and maintenance items Private 'I'_Automobile .r •, judgment

I
preparation
inspection
heart } emperor
Judge Heart R Go Semi remarks
H6 12 24 _
ka ka kata go out
Inspection items Month Month direction
Inspection points ÿ Call port f, 9 ÿ
Month Inspection Every Month Every Law
.. non-adjustable or
ÿ
. . BTDC 5"/950rpm diesel car is point
tun ignition timing
no inspection required
Eta 1,
..
liquid star ÿ ÿ ÿ Must be within the upper and lower reference lines No inspection required for sealed type
emperor
F. l
Mountain Connection state of the terminal
{ Loose and damaged rotten connections
Engagement condition and abnormal noise . ÿÿ

This state of low speed and acceleration .
body
condition of the exhaust
air arc cleaner element

.. Idling speed 950rpm
. .
ÿÿÿ
..
state of the point
original
Oil stains and

oil leak ÿ ÿ ÿ Be on the level gauge between F and L
.
fuel leak ÿÿ
burning
State of link mechanism

movement
.
Condition of throttle valve de easel car
and yoke valve No inspection required
The reserve tank is between FULL and LOW.

cold
amount of water ÿÿÿ
thing
machine
..
refusal The central part of the belt was pushed with a force of about 10 kg.
Looseness and tightness of fan belt deflection of time
damage When new: 6~7mm

5~8.5mm
During normal inspection:.7
..
..
four
Water leak
gas de easel car
..
Condition of metering valve
is: "Pro,
l"
death ,
death,
smoke i Attractÿ
Plumbing damage
Damage to piping, etc.
..
Nirodori 9 U ÿg group
Clogged and damaged diesel car
9[
elephant
charcoal canister No inspection required

vinegar
Check valve function

J.
stomach
..
Catalytic reaction system reduces exhaust gas
ÿ
-I Loose or damaged attachments
.
Corrosion function
Sake I slow down exhaust gas reduction device
i
Piping damage and installation condition
[ Looseness of heat shield plate installation and

and damage
Tokaso Swamp
. ..
and direction indicator • ÿÿ
Completion
Loose and damaged mounting
Mago
Functions
Z] Fuba
ÿ
of the muffler
B-3
Replacement timing Notification method

Regular replacement parts items Replace every year Replace every mileage Replace Remarks
Unit: Year Replacement: 1,000 km Season Method
brake fluid 2 ÿ
Transmission oil and transfer oil 2 30 ÿ
Differential oil 2 30 ÿ
automatic transmission oil Four 60 ÿ
air cleaner element 40 " 20" ÿ
0.5 10 " 5 " ÿ NA engine
engine oil
0.5 5 2.5 ÿ _ turbo car
oil cleaner 10"5"ÿ
Cooling water 2 ÿ
Timing belt 100 ÿ
100 ÿ EFI car
fuel filter
50 ÿ capture car
fuel hose 6 ÿ capture car
.
Note) 1. The replacement period is the year or the mileage, whichever comes first.
2 . " ” mark indicates the replacement time in Sipier condition .
3 ( 1) indicates the item described in the instruction manual, and (2) indicates the item described in the maintenance note .
B-4
engine adjustment
1 engine adjustment
1 -1 supplies
I\ shape letter Model Product Name for road
Engine speed measurement

Wire, Tacho Pulse Pickup
so 09991-87604-000 heart : 09258-00030-000
S.
T. For plugging rubber hoses

Brag set ÿ
hose
Radiator cap Tester adapter

Banzai Co., Ltd. RCT-2A-30S La Jeter , La Jeter
RCT-2A-20A Cab inspection
Total
Iyasaka Co., Ltd. RCT-2-AST
Belt tension gauge / remote cable

Nippon Denso Co., Ltd. 95506-00013 (Gauge) For adjusting the tension of the alternator belt
95506-10040 ( remote cable)
vessel
compression gauge
Checking compression pressure
Banzai Co., Ltd. G-25B
Engine tachometer, Mighty back ÿ Thickness gauge

SK1 E106
1-2 Cooling water level check

1. The cooling water reservoir tank is located under the packing box, on the right side
Located behind the cart panel.

2. The amount of cooling water is the lower limit (LOW) and the upper limit of the reservoir tank.
Check that it is between (FULL)
. mouth reservoir tank

SKI day 001
1-3 Functional check of the radiator

l. Radiator , water pump, radiator hose , heater hose, etc.
Visually check for water leakage from .
2. Or pressurize to 98.lkPa {1.0kg/cni} with radiator cap tester. , Check for water leaks.
C-1
engine adjustment
The pressurization with the radiator cap tester is on both the radiator side and the water valve side.
,,--
It is one.
Roko tile radiator cap tester adapter

Banzai RCT-2A-30S ( radiator cap )
RCT - 2 A - 20A ( water valve )
Yaei Industry Co., Ltd. RCT - 2 - AST
water valve
cap
radiator cap
tester
SKIEI002
1-4 Radiator cap & water bar

sealing surface
Loop function check
1. Radiator cap and water valve cap
, and check if the valve seat surface is dirty or damaged.
Remove the cap
. the water valve.
Visually inspect
Check that it opens and closes by moving it with
SKIE1003
2. Check the water valve with a radiator cap tester .

ÿ Check the valve opening pressure.
of the cap Around 73.6~88.3kPa

{O.75~0.9kg/cnf}
•
Apply water well to the cap seal surface and then test.
attached to the tar.
3. Radiator caster tester
Check the tightness of the .
cup Humidity 98.1 kPa { 1.Okg/ cnf}
SKIEl 004
1-5 Cooling water injection procedure (water injection after cooling system maintenance)
(Reference) • A caution plate is attached to the bottom of the left door (inside).
1. When the cooling water reservoir tank .
Reservoir
cap is opened • tank behind right side skirt panel
2. Open the radiator cap .
C-2
engine adjustment
The straight and radiator caps are for the spare tire.
I have it below.
radiator cap
SKI EI005
3. Water valve cap and bleeder plug (intake manifold) located under the driver's seat
loosen the .
water valve cap breather
9'”
SKIEI006
4. Water valve lever (Imp
left side, bottom) to OPEN.
. The "closed" position is indicated by "SHUT" .
5.Fill the reservoir tank to the full level (upper limit) , Li
and close the reservoir tank cap .
6. Use a water jug to fill the radiator. ,
If cooling water overflows from the bleeder plug, bleeder plug
Tighten the lugs.
hitting 6.86
7. Fill the radiator until the water valve is full .
samurai;. 96 N m
{70 20 kg • cm} Iÿ SKI E1007
Close the water valve cap if water is available .

8. When the radiator is filled with water, close the radiator cap .
Continue
then stop the engine . Top up thewarming
cooling up the engine until the radiator fan operates twice,
water. .
1-6 Cooling water specifications
Cooling water specification
LLC concentration Standard (including snowy areas) 30

(%) cold cold ground
50
Nozomi interpretation husk tap water
all Capacity amount
3.3
Radiator capacity 0.69
Capacity(1)
Reservoir — | FULL 1. o
Tank capacity I LOW 0.15
SKI EIOS
C-3
engine adjustment
1-7 Engine oil level check

1. The oil level gauge is located under the driver's seat, in the service hole
It is located in front of the engine oil pan behind the bar.
2. Stop the engine and check in a wet place. 3. Remove .
the oil level gauge and remove the adhering oil.
-
wipe it off and reinsert it.
oil level gauge
SKIEIOOB
4. The amount of oil must be between the lower limit (LOW) and the upper limit (FULL).
to inspect.
FULL LOW
SKIEI009
1-8 Check Spark Plug

1-8-1 Inspection
1. Check that you are using the specified plug.
SPARK PLUG SPECIFICATIONS
Japan Denso NGK
Wl6EXR-U BPR5ES
SKIEI04
2. Inspect the burnout of the electrode part, burnt condition and breakage of the insulator.
1-9 Alternator belt tension (deflection) check and adjustment

1-9-1 Inspection
ÿ Reference value
Belt tension (deflection) Reference value

When replacing a new belt When inspecting the belt
ka (N)
402~500 304~373
Zhang
(kg) (41~51) (31~38)
Deflection amount (DD) 6~7 7.5~8.5

SKIEIO!i
1. Check the V-belt for cracks, aging and excessive wear.

2. Check the V-belt tension using a belt tension gauge .
(Reference) • V-belts can be inspected by the amount of deflection.
3. When measuring the tension using a belt tension gauge, measure between the pulleys (parts) shown in the figure below.
be.
4. When replacing with a new belt , adjust to the median of the reference values for "installing a new belt".
5. Confirm that belts that have been used for more than 5 minutes are within the standard values for "inspection".
6. Assembling belts that have been used for more than 5 minutes shall be adjusted to the median value of the "inspection" reference value.
C-4
engine adjustment
(Reference J ) When measuring the amount of deflection of the belt, use the specified pulley (alternator pulley ~
Measure the value when pushing with a force of 98N (10kg ) between the water pump pulleys .
Alternator
pulley
ÿ
water pump pulley
Remote
cable
rank pulley
Front
service hall
Front
service hall
SKI EIOIO
Rokoshin Belt Tension Gauge (Nippon Denso)

• 95506-0001 3 (Gauge)
• 95506- 1 0040 ( remote cable )
1-9-2 adjustment
1. Loosen fixing bolt A (alternator upper bolt ) , B (Alter
and alternator lower bolt ).
2. Insert a 0 screwdriver , etc., into the area shown in the diagram on the right to turn the alternator .
pull the motor toward, you to adjust the belt tension.

3. Tighten the alternator fixing bolts A and B.
Straight bolt A
29.4× 5.9N•m {300 60 kg cm}
Bolt B
39. 2 Sat 7. SN m {400 80 kg cm}
4. Check the belt tension (or deflection) again. .
1 -10 VALVE CLEARANCE INSPECTION

1. Remove PCV hose and resistive cord .
C-5
engine adjustment
2.From the service hole cover , cylinder head Left service hall
remove the bar.
(Three r
3. Remove the rubber cap from the timing belt cover No. 1.
vinegar.
m cap
SKI EIOl5
4. Rotate the crankshaft forward (clockwise) and the camshaft

Pulley timing mark and timing belt Notch
Align the sight glass on cover No. 1 with the alignment mark on cover No. 2.
be.
unit · This confirmation work can be done using a mirror or the like while the vehicle is in the vehicle.
5. At this .
time, check that the compression top dead center is reached through the ignition timing inspection window.
inspect.
SKI EIOl6
The garden and timing marks are pink.
Service hole under the seat
ignition timing mark

SK1 EI017
C-6
engine adjustment
6. Check and adjust the valve clearance using a thickness gauge .

in wet and cold conditions
(IN)
0.18 Sat 0.0511111
(EX)
0. 25 0. 0511111
Trouble • Adjust the valve clearance when cold.
SKIE101 8
1 -1 0-1 measurement, adjustment part

ÿ No. 1 cylinder compression top dead center
1st cylinder 2nd cylinder 3rd cylinder
IN EX IN EX IN EX
ÿ ÿ ÿ ÿ
SKIEIOI
SKIEI01 9
ÿ 1st air exhaust top dead center
1st cylinder 2nd cylinder 3rd cylinder
IN EX IN EX IN EX
ÿ ÿ
SKIE102
SKIEI020
1 -1 1 Check compression pressure

1. Fully warm up the engine ( until the fan motor operates once).
2. Turn the IG switch to "OFF".
3. Remove all resistive cords and spark plugs .
4. Install the compression gauge .
\ Cylinder head cover
Service Hall /
SK1 E1021
C-7
engine adjustment
(Reference) • Compression gauge

• G-25B (handled as Banzai)
Compression gauge
SKIEI022
5. Fully open the throttle valve and choke valve , rotate the starter, and check the pressure with the compression gauge.
Measure the .
compression force Wet 1 O.Okg/cnfÿ400rpm or more
Each cylinder difference within 1.5kg/cnf
Around the time ÿ Use a fully charged battery and do it in as short a time as possible.
1-12 Ignition timing check and adjustment

1-12-1 Standard value
ÿ BTDC5°Sat2 / 950rpm
1-12-2 Inspection and adjustment

1. Install SST on the ignition coil .
Country 09991-87604-000
2. Allow the engine to warm up completely. (The fan motor operates once
until)
09991-87604-000
SKIE1026
3. Attach the engine tachometer to the SST and turn on the timing light.
Install the
SKIEI023
C-8
engine adjustment
4. Remove the distributor vacuum hose and remove the plug

Use a hose set to plug the disconnected hose.
be.
ÿÿ Tai Min
/
Client
09258 Psychic
Declaration 09258-00030-000 5.
, ignition timing
Confirm that the idle speed is within the standard value.
to the timing mark on the flywheel on the TIM side.
indicator on engine rear end plate
inspect.
SKI E1024
Co- timing marks are pink.
Timing light
ignition timing mark

Sl<EI025
Wet BTDC6°F2 / 950rpm

6. If it is out of the standard value , turn the distributorto adjust the ignition timing to the standard value.
7. Attach the distributor vacuum hose .
1-13 Checking and adjusting the idle speed

1-13-1 Standard value
wetness 950 sat 50 rpm
1-13-2 Inspection
1. Install SST to the ignition coil.
snow 09991-87604-000
2. Fully warm up the engine. ( Fan motor operates once
until)
09991-87604-000
SKIE1026
C-9
engine adjustment
3. Move the air cleaner intake lever to "summer" intake .

switch to
Four .
Install an engine tachometer on SST .
SKIE1023
1-1 3-3 adjustment

1. Turn the throttle adjusting screw to adjust the idle
Humidity 9 .
50 Saturday 50rpm
Trouble • Fan motor operates when idling speed is adjusted

stop work if .
•Do not apply an electrical load such as a headlamp.
1 -1 4 Idle CO, HC concentration check, adjustment

1-1 4-1 Inspection
1. Carbon monoxide (CO) at idle with the engine fully warmed up (until the fan motor fires once) ,
Check the emission concentration of hydrocarbons (HC) with a CO, HC tester .
wetness Co 1.5 certified: g %
HC 900ppm or less
1-1 4-2 adjustment

.
1. Completely warm up the engine ( until the fan motor operates once) and adjust the idle speed.
2. Turn the mixture adjusting screw to
Humidity to adjust HC .
Co 1.5 magazine: g %
concentration
HC 900ppm or less
C-10
engine adjustment
1-14-3 Adjustment
procedure 1. Perform racing (approximately 2000 rpm) once, return to idling, and then turn the mixture adjusting screw to adjust the co
concentration within the standard value. At this time, the HC concentration should be within the standard value. After adjustment,
2. perform lacing (approximately 2, OOOrpm) and measure CO and HC concentrations again . Trouble • At this time, if the idling
speed is out of the standard range, adjust it again.
1-15 Throttle positioner inspection and adjustment 1-15 -1
Inspection 1.Pinch and remove the hose connected to the throttle

positioner while the vehicle is idling so as not to suck in air. 2. When the
disconnected hose is reconnected, it will start idling .
Measure time to return. About 5
seconds
Ba
KIEI029
Around-21-15
Adjustment
•Make
sure to perform
the adjustment after the engine is warmed up ( until the
fan motor operates once) .
• To be done after idle adjustment, CO and HC
adjustment. 1. Remove the vacuum hose connected to the throttle
positioner and plug it to prevent air from being sucked in. four
09258-00030-000
2. Adjust the engine speed to the standard value with the adjustment screw.
wet 1 , 800 rpm 100 rpm

3. After opening the throttle and holding it at about 2,500 rpm for about 15 seconds
Throttle back. 4.
Confirm that the engine speed reaches the reference value. 1.
~3. repeat the work. 5. Next, check how long it takes for the
engine speed to return to idle speed after connecting the vacuum hose to
the throttle positioner. ÿ About 5 seconds
C-11
power unit
Noisy week •Keep fire away when working on the fuel system.
•When removing the fuel hose, prevent the fuel from scattering. .
•Do not remove the water hose when the cooling water is hot .
Le
SKIE201
1. Jack up the vehicle.

2. Remove the fuel tank cap and remove the , Relieve pressure in fuel line .
battery negative terminal .
3.4. Noise •Do not remove the radiator cap or drain plug when the coolant is hot .
Drain cooling water.
5. Remove the front exhaust pipe.

(Refer to C. 6-3 (page C-55))
6. Remove the timing belt.
7. Remove the intake manifold Ay W/ carburetor.
(Refer to C. 6-1 ( page C-51))
cold
qi
"
ÿCode ÿ Coil registration

ÿCode Resistive _
ÿ
[Next]
ÿÿ
Poor) Ding
ÿEi ÿ'
// ÿ Hose ( 2 : for distributor ventilation)
ÿHose vacuumÿ
ÿ Distributor Ay
ÿ Hose ÿ ÿ water outlet
Harness Connectors
ÿ
ÿ Cover SIA, cylinder head

ÿGasket cylinder head cover
ÿ
........ ÿHead Ay, Cylinder

.... ÿGasket cylinder headÿ
* : Non-reusable parts
Unit: N•m { kg•cm}
SKIE2001
C-12
power plant
2-1-4 Points of removal 1.

Remove ÿ cylinder head Ay.
(1) Remove the cylinder head Ay along with the exhaust manifold Ay from the vehicle bottom side.
2-1-5 Installation points 1.

Use a scraper to scrape the cylinder block . , Clean the gasket mounting surface of the cylinder head.
After that, install a new ÿ cylinder head gasket . Do not
drop co- gasket
Completely
shavings
remove
intoforeign
the cylinder
matter,
block
oil, etc.
.• from the mounting
surface of the cylinder head gasket .
2. Install ÿ cylinder head Ay.
(1) Install the cylinder head Ay together with the exhaust manifold Ay to the cylinder block . (2) Tighten
the cylinder
eight bolts to Ay,
head the apply
specified torque. After
the specified applying
torque enginetimes
two or three oil to in
thethe
screw
orderpart andin
shown bearing surface
the figure of the
on the right.
Tighten with a louque.
SKIE2002
2-1-6 Work after installation

1. Install the intake manifold Ay W/ carburetor.
(Refer to C. 6-1 (page
C-51)) 2. Install the timing belt.
(See C. 3-1 (page C-24))
3. Install the front exhaust pipe .
4. Inject cooling water.
(Refer to C. 1-5 (page
terminal.
C-2)) 5.
Attach
6. Jack
thedown
battery
thenegative
vehicle. 7.
Check and adjust the engine (Refer to
Section C.1 (page C-1)) .
C-13
power unit
2-2 Removing the piston , Mounting

2-2-1 Preparations
ÿ shape letter Model Product Name for road
s
ÿ_ 09221-87207-000
Remover , breaker service Ton pin
Removal and installation of piston pin
09221-87209-000
T. [ Ni Coco I Remover & Replacer Stone Pin Removal and installation of piston pin
Podey
Instruments Torque wrenches, Cylinder gauges, Caliper gauges , Micromakeup, Thickness gauges, Breath gauges
Tools Piston ring Expander, brace
Grease Engine oil

SKI E202
2-2-2 Work before removal

2. Remove the intake manifold Ay W/carburetor.
3. Remove the cylinder head Ay.
(Refer to C. 2-1 (page C-12) )
4. Remove the oil pan S/A.
C-14
power plant
2-2-3 Removal and installation procedure
engine oil
ÿ
engine oil
0ÿ
ÿ Three 9 Il1 1] this / _._ÿ 6.01370 Sat 601 I
en gin oil
ÿBearing
ÿ Cap, connecting rod
ÿÿÿ Piston S/A, W/ pin

ÿ
“O”
ÿÿÿ Ring Piston
ÿ
ÿÿÿ Ring ÿÿÿ

Rod connecting
ÿ
Unit: N•m {kg•cm}
ÿÿÿ Piston
SKI E2003
2-2-4 Main points of removal
Masashi
2. Remove theOrganize by Wise
ÿHistone S/A cylinder
.
1. Remove (1) the connecting rod cap and (2) the bearing.
pin and ÿConnecting rod as a set using a hammer handle, etc.

put out.
toolTadashi
3. Use the piston ring
• ÿ piston rings,
to remove
.
ÿ Remove the oil ring.
C-15
power unit
Four . ÿRemove the piston using SST in the following manner.

Tadashi . 9221-87206-ooo@
09221-87207-000® Piston pin
(1) Set SSTÿ on the piston pin.
SKI E2005
(2) Set to SST® in the above state. , SST using press

Pull out the piston pin into the ®.
Trouble • Remove the spacer .
way direction
Bore selection code
2-2-5 Inspection
nine shaft
( 1 ) Cylinder
Gon
direction
1. Find the difference between the maximum value , Measure the 6 points shown in the right figure and
and the minimum value using a cylinder gauge.
If the limit is exceeded, replace the cylinder block .
ÿ::
Scrap 0 .2nm
[Reference] • Cylinder block Stem quasi inner diameter
68.00~68.03n tray
Piston mating code Cylinder inner diameter (mm)
1 68.00 or more to 68.01 or less

2 Over 68.01 to 68.02 or less
3 Over 68.02 to 68.03 or less SKI E203
2. Use a cylinder gauge to measure the inner diameter , ellipticity,

Measuring once taper .
(Reference) • Ellipticity
AB or ab
• Taba once
Aa or B-b
Garden 0. 03nm
SKI E2007
C-16
power unit
(2) Piston
ÿ Piston cleaning
1. Use an old piston ring, etc. for carbon in the ring groove.
Clean the .
2. carbon from each part with a cleaning .
solution, etc. Do not use
Country • anything with hard bristles such as wire plastics.
thing.
SKI E2008
ÿ Piston pin oil clearance check

1. Use a caliper gauge and a micrometer to
Measure the illumination clearance.
wetness 0.005~0.01 1 11111
SKI E2010
® Piston outer diameter measurement

1. At a distance of 11.5 mm from the lower end of the skirt of the piston, insert the pin hole
Measure points perpendicular to and .

dampness 7. 965~67.995nm
I
SKI E201 1
(3) Cylinder and piston oil clearer

inspection
1. Measure the outside diameter of the piston and the inside diameter of the cylinder (figure on the right).
Measure the clearance. If the limit is exceeded, the vist

Replace the engine or cylinder block.
Wet 0 .025~0.045nm
Scrap 0 . 10nm Cylinder inner diameter
Measurement points
( Piston
idea
perpendicular direction)
SKI E201 2
C-17
power unit
2. When you replace the piston or cylinder block

After replacement, check the oil clearance again .
(Refer to J. Oil clearance in piston and cylinder block).
ÿ
The clearance should be the maximum in the thrust direction of the cylinder .
Subtract the piston maximum outer diameter (basic diameter) from the small inner diameter.
It is a thing.
cylinder inner diameter
68.000 or more to 68.010 or less

Over 68.010 ~ 68.020 or less
Outer diameter of piston
67.965 or more ÿ67.975 or less

Over 67.975 ~ 67.985 or less
B/ SKI E2013
Over 68.020 ~ 68.030 or less 67. Over 985 to 67,995 or less
SKI E204
selection code
3. Selection of oversize (0/S) piston
(1) Measure the inner diameter of the , polished over limit
cylinder and the outer diameter of the piston .
Select and use stone.
Boring finish dimension = (0/ S measured value of piston outer diameter)

+ ( oil clearance) - (honing margin 0.02 plate)
SK1E2014
(4) Inspecting the clearance between the piston ring and the ring groove
1. Using a thickness gauge, measure the clearance around the circumference of the piston.
Measure across.
Standard value limit

0.03~0.07 0.12
0.02~0.06 0.11
SKI E205
(5) Piston ring gap inspection

1. Place the piston ring about 45Dlll from the top of the block.
ton, and use a thickness gauge to measure the, clearance .
Measure.
limit
|\ reference value
EF-CK
No. 1 0.25~0.40
0.65
No. 2 0.40~0.55
0.2~0.7 (Riken)
oil l.o SKI E2016
0.2~o.5 (day pi)
SKI E206
C-18
power unit
(6) Connecting rod bearing oil clearance check

1. Clean the inner and outer surfaces of the bearing, the connecting rod end and .
, bearing
the crank pin . 2. Place a press gauge on the bearing.key
Attach the bush.
press gauge
Spring 36. 0 Sat 6. ON m {370 Sat 60 kg • cm}
Country • Do not rotate the crankshaft during measurement.
SK1 E201 8
to measure .
3. Remove the bearing cap and measure the width of the press gauge.
stomach
0.020~0.044Rl11
Bandit 0 07Rl11
---SKIE20l9
2-2-6 Points of installation

1. Remove the ÿ piston and ÿ connecting rod as follows.
Assemble.
to match .
(1) Front mark of piston and connecting rod
front mark
SKIE2020
(2) In the pin holes of the piston bin and connecting rod
Apply engine oil , using SST , press fit .

. 9221 -87206 Ichibu
09221 -87207 — Monument
around the timeThe piston should be press-
fitted at room temperature.
.
Do not apply pressure at an angle. mouth pin
SSTÿ
insert into the cutting rod .

(3) Set the piston pin in the SST@ and tighten the piston and connector.
SK1 E202 1
C-19
power plant
(4) In the state of (3), set to SST@ and use the press to
.
Press in until it hits the pacer.
SST®
SKIE2022
2. Assemble the ÿ piston ring and ÿ oil ring as follows.

find.
(1) Piston ring assembly
ÿ Hold the piston ring tool with the identification mark facing up.
Use and install. (There are two identification marks , R and N.
kind)
ÿ break surface
/
No. 1
I )
No. 2
I mouth
SKIE207
Use the same manufacturer for the ring and piston rings .
that
(2) The joints of each ring are thrust in order from No. 1 ring.
ÿRotate
direction, anti-thrust direction and 180 and assemble.
SKIE2024
(2) Oil ring assembly

ÿ Assemble the two rails above and below the oil ring in the same way as the piston ring.
3. Assemble ÿpiston S/A with pin as follows.
(1) Check the direction of the joint of the .
piston ring (2) Apply vinyl tape to the connecting rod bolt
winding etc., Cylinder and crankshaft damage
(3) .
Emissions on the sliding surfaces of the piston and connecting rod
Apply engine oil .
SKIE2025
C-20
power unit
(4) With the front mark of the piston facing forward, insert it into
, combination
the block using the piston ring tool . Make
as when
the same
disassembling
the base, piston and each cylinder.
--- SKI E2026
4. (6) Bearing 5.
(5) Assemble the connecting rod cap as follows.
(1 ) Install with the front mark facing up, and apply a small amount of engine oil to the
screw. (2) Alternately tighten the left and right nuts to the specified torque. 36.0 6.0 N•m
{370 60 kg cm} Conrod thrust clearance inspection
6.
(1) Measure the thrust clearance using a dial gauge
or thickness gauge. wet bandit
0.15~0.2511111
0.3011111

1. Install the oil van S/A.
(See C. 4-3 (page C-43).)
2. Install the cylinder head Ay .
3. Install the intake manifold Ay W / carburetor.
( Refer to C.6-1 (page C-51))
4. Install the timing belt .
C-21
power plant
2-3 Crankshaft front oil seal removal and installation

letter
ÿ shape Model Product Name for road
Rebracer , crankshaft front oil Oil seal press fit
s white 09223-87202-000
s
T.
seal
SKt E208

ÿÿ
ÿPulley _ ÿ Crankshaft timing pelt

(2) Flange ..,.. Crankshaft Timing Belt Top Lee
ÿ
(3) Seal , Type T Oil seal

SK1 E202II

1 ÿRemove the type T oil seal in the following procedure.
C-22
power plant
(1) Cut off the lip of the oil seal . (2) Wrap .
tape around the flathead screwdriver . , Put a waste cloth against the crankshaft and pry the oil seal out.
vinegar.
Discard] • After removing the oil seal, check that there are no scratches on the chamfered portion of the crankshaft. (wound
If there is, fix it with sandpaper (#400) .

1. Install the ÿ type T oil seal according to the following procedure .
(1) Apply engine oil to the lip of a new oil seal. (2) Use the SST .
and timing pulley set bolt .
the oil seal to the end face. Snow .
09223-87202-000
SKI E2031
2. (2) Crankshaft timing belt pulley flange

ÿCrankshaft timing bell
Install the top pulley.
Around the time] • Crankshaft Timing Belt Toppu
outside
The leaf flange should have the warped side facing the block.
Decree = II
to install . crank
Shaft
timing
pulley side

1. Install the timing belt.
C-23
Cam, valve mechanism
3 Cam , valve mechanism

3-1 Remove and install timing belt
3-1-1 Preparations
, Torque Wrench
1 Instruments and others I Thickness gauge, M6 bolt
SKI E209
3-1 -2 Work before removal

1. Jack up the vehicle 2.
Remove the negative battery terminal.
.
3. Remove the service hole covers (front side, left side).
ÿ 9
1
I
`
: 29.0 {300}
| /
IT : 39.o { 400 } |
/
pressure 39 three
Unit: N m {kg cm}
...ÿ Belt V ( for air conditioner)

ÿ ÿ Cover S/A, timing belt ....ÿ Flange ÿ No. l
... ÿPelt V ( for alternator)

ÿ
crankshaft timing pulley
ÿ
ÿ Alternator Ay ........ÿ TENSIONER S / A, TIMING

...... ÿ Pulley , water pump ........9 Belt timing
ÿ
...... ÿPulley ÿ Crank shaft
SKI E2033
C-24

1. Stop rotation with a screwdriver , etc. ÿ Water pump
Remove the pulley .
2. Remove the timing mark cover and remove the ring with a screwdriver or the like .
ÿ Crankshaft
remove the pulley .
3. Remove the ÿ timing belt tensioner S/A. Alignment mark

(1) Set the No. 1 cylinder to compression top dead center.
ÿ Temporarily install the crankshaft pulley mounting bolt. notch]

and
, rotate the engine in the forward (right) direction
Check the punch mark on the timing belt pulley .
Align with the notch in timing belt cover No. 2
Ru .
ÿ At this time,Crankshaft Timing belt

MAKE
The punchSURE THE
mark onMARKS MATCH
the pulley is aligned with the oil pump.
SKI E2036
(2) If you reuse the timing belt, mark the printed
. line on the back.
(Yellow " one") remains. (3) If the above .

printed line disappears, the No. 1 cylinder compression top dead
Ma ”`
Camshaft timing belt pulley
and crankshaft timing belt pulley ÿ
Write the punch mark and matching mark on the back of the
belt with a chalk or the like.
(4) Remove the bolts , timing belt tensioner
and remove the S/A.
SK1 E2037
4. ÿ Remove the timing belt.

Shigeru • When removing the belt, never pry it with a screwdriver or the like.
Do not
•When reusing the timing belt,
Choke on the back of the belt to indicate the forward rotation direction.
Write down the arrow pointing
SKI E2038
C-25
cam, valve mechanism
3-1-5 Inspection
(1) Timing belt Inspect each
back
partrubber.
of the timing
(2) Root
belt
cracks,
and replace
canvasitdelamination,
if it is damaged
andascracks.
follows.
(3)1 Worn
(1) Crack
canvas,
in
missing teeth. ( 4) Abnormal wear on the side of the belt. 2. Even if no external
damage can be confirmed, replace the belt in the following cases. (1) Continuous
exposure to water due to water pump leakage, etc. (2) When there is a lot of oil
on the belt, and expansion of the rubber is suspected. (3) When it seems that
excessive force is applied to the belt due to sticking on the camshaft side .
(2) Check for locking of the timing belt

surface of the belt, . tensioner
turn the tensioner
bearing, abnormal noise, and scratches on the contact
(3) Visually inspect the timing belt

pulley for damage or deformation.

1. Pay attention to the following items when handling the .
timing belt:
break
Do not
thebend
cord the
of the
beltbelt
at a.•Do
sharp
notangle,
allow as
oil,itgrease
may or water to adhere
to the belt, as this will shorten the life of the belt .• Never pry the belt with
a screwdriver or the like.•When rotating with a belt, be sure to do so on the
crankshaft side.•When reusing the belt, align the direction of rotation
(the arrow on the back of the belt when it is removed) and attach it.
that
2. Install the ÿ timing belt according to the following procedure. Alignment mark
( )1 Cylinder 1 is set to
depression
compression top dead center. ÿ Make sure that the punch

mark on the camshaft timing belt pulley and the
matching mark on the oil pump are aligned .
SKI E2036
ÿ Confirm that the punch mark on the crankshaft

timing belt pulley and the notch on the timing belt
cover No. 2 are aligned.
C-26
(2) Align the alignment mark on the back of the timing

belt with the punch mark on the crankshaft timing belt pose
pulley and the punch on the camshaft timing belt remark
pulley . Install by aligning with the marks .
SKI E2037
3. Install the ÿ timing belt tensioner S/A in the following procedure.

Install. (1)
Remove the resin cap attached to the oil pump body .
vinegar.
(2) Temporarily attach the timing belt tensioner (3) .

Insert an M6 bolt (pitch 6 Dill, length 20-30mm ) into the hole
where the resin cap was removed . Screw it in until it is
full. Gardenthe
• ÿbolt
Insert
anda the
thickness
tensioner
gauge
to between
prevent the
theroller
tip of
“
of the tensioner from being damaged.
(4) Humidity 11~ 13nm to measure the gap between

the outside
. of the oil pump body and the
tensioner (5) The
Tighten
timingwith
belt tensioner S/A
SKIE2042
4. ÿ Crankshaft timing belt bushing

the engine.•Since
the flange has
directionality, install it in the direction shown
in the right figure. ”
ÿ
Crankshaft
timing
pulley side
SKIE2043
5. After removing the timing mark cover and using a

screwdriver or the like to stop the ring gear from
rotating, install the ÿ crankshaft pulley .
C-27
Cam , valve mechanism
6. Stop rotation with a screwdriver, etc., and ÿ Water pump

Install pulley .
7. ÿ V-belt (for alternator ) and ÿ V-belt (for air
(for compressor ) and adjust the tension. .

1. Attach the service hole covers (front side, left side).
2. Attach the battery negative terminal.
3. Jack down the vehicle.
C-28
3-2 Removing and installing the camshaft oil seal
3-3 Preparations
shape letter Model Product Name for road
09278-87201-000
s Tool, timing belt For fixing camshaft timing pulley
Holding
s
09707-87302-000
T. Remover & Rebracer , For press-fitting oil seals
spring bush
Grease I engine
instrument torque oil, silicone pound
wrench
SKIE210

(See C. 3-1 ( page C-24 ))
2. Remove the engine under cover Ay.
(Refer to C.6-3 ( page C-55 ))
C-29
swamp
ÿ 5.5 countries]
\@i ÿ
IT:9.o {90}I
engine oil
Weight: 98.0 sat 10{10. three
...... ÿPulley ÿ cam shaft timing belt

ÿCover S /A, cylinder head
ÿValve rocker shaft & valve rocker arm
ÿ Hoses (2 hoses: for ventilation of the taste remover)
ÿ Distributor Ay
ÿ Cover Timing belt No2
ÿ
ÿPlate oil seal ÿ

......ÿ Seal ÿÿÿ ÿ type T oil
Unit: N•m{kg•cm}
Ring, Camshaft Thrust
Sl<IE2044

1. ÿCamshaft timing belt Pulley to SST
Use to prevent rotation and remove.
SST
snow 09278-87201-000
SKIE2045
C-30
2. ÿ Type T oil seal and ÿ Camshaft slide

Remove the string as follows. Flange bolt
(1) Remove the flange bolts for fixing the thrust ring.
SKI E2049
(2) Distributor mounting part at the rear end of the camshaft

A box wrench with a width across flats of 23 mm and an extension
Use a bar and hit with a hammer.
clear Make sure the flange bolts are removed.
to go from

1. Install ÿ camshaft thrust ring and ÿ type T oil seal as follows.
(1 ) Apply engine oil to the camshaft journal and thrust ring mounting area.
(2) Align the bolt holes of the thrust ring and the cylinder head.
Thrust ring
and insert the thrust ring, and tighten the flange bolts.
.
Temporarily tighten bolt
Kaoru Koroko] • Flange bolt is timing belt cover
Na. 2After installation, fully tighten.
SKI E2046
(3 ) Apply engine oil to the sealing surface of the oil seal. ,

Using SST to press fit an oil seal .
gakishi 09707 -87302-000
Porto M1 0 length under neck 40~50nm
around the time When reusing the oil seal , remove the rubber part
(4) Press it in until it feels .
like it is on the bottom, remove ,the bolt
and hammer it.
.
Check the press fit condition by lightly tapping the SST from the top with
C-31
2. (1) Insert the camshaft timing belt pulley into the SST.
Use to prevent rotation and install.
Country 09278 -87201 -000 SST
3-3-5 Work after installation l.

Install the front exhaust vibrator.
( See C.6-3 (page C-55) ) 2.
Install the engine under cover Ay. 3. Install the
timing belt.
(Refer to C.3-1 (page C-24))
4. Adjust the ignition timing.
C-32
3--4 Camshaft removal and installation

3--4-1 Preparations
09278-87201-000
s Tool, timing belt For fixing the camshaft quimming pulley
Holding
s
09707-87302-000
T. Remover & Replacer , For oil seal press fitting

spring bush
instrument torqueoil,
Grease I Engine wrench
silicone pound
SKI E21 1
3-4 2 Removal - Pre-work

2. Remove the intake manifold Ay W/ carburetor.
3. Remove the cylinder head Ay.
3-4 3 Removal - , installation instructions
Todo 10 { 1 000 1 00} ]
ÿ Taste:
three
`three
...,... ÿPulley Cam Shaft Timing Belt
ÿ
ÿValve rocker shaft & valve rocker arm

ÿCover Timing Belt No.2
ÿ
ÿPlate ...,... ÿ Oil seal

ÿSeal ÿ type T oil
...,...ÿ Ring ÿ ÿ Camshaft thrust * : Non-reusable parts
Shaft ÿ Cam Unit: N m) kg cm}
SKI E2048
C-33
Machine Translated by Google Cam , valve mechanism
3--4--4 Points for removal

1. (1) Use SST to stop the camshaft timing belt pulley
from turning, and then remove it.
SST
SKIE20!ll
2 a
Si
..
one
door vinegar door
BooTyo E Sha Sha ,door strong required outside
vinegar ÿ biri
hmmsquid remfixed use Ruff's
centre Knowledge ) take
Pick up off
. ÿÿ
say in
.ÿ
three
ÿ ÿ
Genus 2
Si Touya centre De i vinegar

one in one
surfacewidth the boy vinegar red vinegar Lobe

Phosphorus attachment
2 } end,ÿ zu
sum Lukewith a rigo D takeConfirmed hand
Five
after group Kumare
door ÿ Lower Jibichi child to
When
use To 23 Shira lineJiu child When .
SKI E2053
3-4-5 Installation points
procedure
Assemble . the ÿshaft,
cam ÿ cam shaft thrust ring and ÿ type T oil seal according to the following
(1 ) Apply engine oil to the camshaft journal and thrust ring mounting area, and then remove the camshaft.
insert. (2)
Align the bolt holes in the thrust ring and the cylinder head
Insert the thrust ring at the , and insert the flange bolts.
same time and tighten it
temporarily.
timing
Afterbelt
installing
cover ,the
fully tighten the flange
port. .
(3 ) Apply engine oil to the rib surface of the oil seal,

Press in the oil seal using SST .
snow 09707-87302-000
Porto M1 0 Neck Length 40~ 50111t1
unit • When reusing the oil seal , remove the rubber part
(4) Press-in to the bottom, .
remove the bolt, and hang . ,
Check the press fit by lightly tapping the top of the SST with a marker .
2. (1) Attach the camshaft timing belt pulley to the SST.

B SKI E2055
Use to prevent rotation and install.

snow 09278-87201-000
SST
SKI E2051

1. Install the cylinder head Ay .
C-35
3-5 Removing and installing the valve stem oil seal

09202-87002-000
valve spring retainer lock
Remover & Replacer,
remove and install
valve cotta
s
s
one 09208-87701-000
Remover, valve stem
oi) receipt
Remove valve stem oil seal
T.
09201-87202-000
REPLACER , VALVE STEM Press fit of valve stem oil seal
oil seal
Instrument I Torque wrench

Sl<IE212

3. Remove the intake manifold Ay W/ carburetor .
4. Remove cylinder head Ay.
C-36
engine oil)
ÿ
Q.
ÿ One-bu
'
ÿ--£
/
Engine oil
Shaft & rocker arm

........ÿ Lock ÿ valve spring retainer
........ÿ Retainer valve spring
ÿ
........4 Spring, Compression

Unit: N•m{kg cm}
........ÿ Seal valve stem oil
ÿ
SKI E20!ill

1. REGISTRATION WEEK • Protect your eyes with safety glasses during this work.
• Be careful not to let springs, etc., protrude.
ÿValve spring retainer lock ÿValve spring retainer ÿCompression
Remove the spring (valve spring) and ÿ valve stem oil seal as follows.
Troubleshooting] •Retainer lock, valve stem oil
Remove and install seals one cylinder at a time, I ÿ 1\ / SST
It should be done at the top dead center of the piston.
,
(1) Valve spring retainer lock using SST
Remove , Valve spring retainer , kombu
the tension spring (valve spring)
vinegar.
Darkness 09202-87002-000
Garden • Clean the oil return hole in the cylinder head with a cloth, etc.
Keep your head down and don't drop the retainer lock SKI E2057
to be used.
C-37
(2) Use SST. , Remove the valve stem oil seal
Declaration 09208-87701-000
SST
He ÿ SK1 E2058

1. ÿValve Stem Oil Seal
Install using SST.
(1) (]ill 09201-87202-000
SST
SKI E20511
SKI E2060
2. Use SST to , ÿ Compression spring, ÿ Spring

remove the spring retainer and ÿ retainer lock .
Attach.
Negligence 09202-87002-000

.Install the cylinder head Ay .
1 (Refer to C. 2-1 (page C-12))
3. Install the front exhaust pipe.
C-38
Lubricator
4 Lubricator
4-1 Removal and installation of oil pump
ÿ Torque wrench
SKIE213

1. Drain the engine oil.
3. Remove the oil pan.
3]
'///
/ '
/
®
1:19.o{19 shout
this`*
| T:8.o{80} |
ÿ Strainer S/A, oil

ÿ
ÿGasket oil strainer
Unit: N•m!kg•cm}
....ÿPump Ay, Oil
....ÿGasket ÿ oil pump
SKI E2062
4-1--4 Work after installation

1. Install the oil pan.
3. Top up engine oil.
C-39
Lubricator
4 -2 Oil pump disassembly and assembly
4-2-1 Preparations
ÿ shape
letter Model Product Name for road
s
s mouth09223-87202-000 _ Rib racer, Crankshaft Oil seal press fitting
T. Front oil seal
SKIE214
4-2-2 Work before disassembly

1. Remove the oil pump.
4-2-3 Disassembly and assembly procedure
:] Five .,ÿ,.
Sahÿ ÿ Wordsÿ
Unit: N•m {kg cm )
^*
.... ÿ Ring, ''O''
ÿ) Screw
( 3) Cover , oil pump
.... ÿ Gear, oil pump drive
® pin, cotter
® Retainer oil pump relief
ÿ
ÿ Spring, compression valve

®Pulve , oil pump relief
.... ® seals , type ''T “ oil
SKI E2063
C-40
Lubricator
4-2-4 Inspection
1. Align the mark on the oil pump drive gear with the cylinder brake.
mark
Install it on the body with the lock side facing up.
SKIE2064
2. Tip clearance inspection

(1) Use a thickness gauge , drive gear and rotor
to measure the tip clearance.
wetness 0. 1 7~0. 2411111 ( average of 9 locations)
(l[IJ 0.35nm
3. Body clearance inspection

(1 ) Using a thickness gauge , Clear rotor and body
Humidity .
measuring0.10~0.185nm
lance
Straight. . 25 nm
4. Inspection of relief valve

(1) No significant wear or damage to the relief valve and retainer .
Check whether
Thoughts on Kasumi
gate ®
SKIE2067
4-2-5 Assembly
1. After applying engine oil to the lip of a new ÿ type T oil seal , assemble it using SST.
Kick.
snow 09608-87302-7ÿ
09608-87302-13ÿ
2. Align the marks on the ÿ oil pump drive gear so that the mark faces upward on the cylinder block side.
Attach to the body immediately.
3. Attach a new O-ring (1) to the groove of the oil bomb cover , and attach it to the 3 raised marks on the cover (fixed
fixing the O-ring with .
C-41
Lubricator
4-2-6 Work after assembly

1. Install the oil pump .
(Refer to C. 4-1 (page C- 39 ))
C-42
Lubricator
4 -3 Remove the oil pan, attachment
4-3-1 Preparations
ÿ shape letter Model Product Name for road
s
s
T.
under Cutter ÿ
09032-00100-000
Oil van seal
oil van removal
instrument torque wrench
Tool scraper, shift gun
Oil slip 1207F

SKIE2U

2. Drain the engine oil. 3.
Remove the engine under cover light.
.
| T:29.4 5.9
B: Kokosan 60
ÿ
| T:8.0 {80} |
* ®
spirit
..... Q) Belt ÿ V (for air conditioner compressor )

...ÿ Compressor Ay , ÿ W/Magnet Clutch
Bracket compressor ÿ
( 4) Clutch housing under
ÿ Unit: N•m{kg•cm f
Cover ........ (5) Pan S/A, oil
SKIE2070

1. (2) Compressor Ay Wise magnet , Secure to the body with a harness, etc.
Separate the clutch from the bracket
determine .
C-43
Lubricator
2. Remove ÿ oil van S/A in the following manner.

(1) Separate the oil pan S/A from the cylinder block
using SST. Country 0 9032-00100-000
4-3-5 Installation points 1. ÿ

Assemble the oil pan S/A as follows.
( )1 Scrape off the gasket adhering to the oil bun.
Clean with a parser, wire brush, etc.
Children] • Make sure there is no gasket left in the groove of
the oil pan .
(2) Liquid gasket ( ThreeBond 1207

F) is applied as shown in the right
figure and installed.
of liquid gasket.•Apply
*Apply ¢3~4 width
to the inside around the
bolt holes so that there is no lack of
coating.•Assembled within 15 minutes after
applying liquid gasket
be ÿ
•Make sure that the gasket applied to the oil

pan does not adhere to other parts.
2. (1) Attach the V - belt (for the air conditioner compressor ) and check
.
the tension according to the position shown in the diagram on the right,
and then adjust the tension.
When replacing a new belt When readjusting a belt
Immediately after assembly 6.0~7.0mm

| 7.5~.5mm
after driving 8.5~12 mm
SKI E225

1. Install the engine under cover light. 2. After
installing a new gasket and tightening the drain plug to the specified torque, add engine oil.
be.
C-44
Lubricator
4--4 Oil pressure test
4--4-1 Preparations
ÿ shape letter part number , Product name for road
so _
s
T.
Instruments Engine tachometer, pressure gauge

09991-87604-000
WIRE, TACO VALVE PICKUP
Engine speed measurement
SK1 E224
4-4-2 Functional check

1. Install SST and engine tachometer.
snow 09991-87604-000
2. Warm up the engine .( radiator fan runs once ).
until)
3. Remove the engine under cover left.
SKI E2076
4. Remove the oil pressure switch and use a pressure gauge (thread diameter t
__--B
PTl/8) . I
ÿ/
[
5. Start the engine and measure the pressure at each revolution.

Humidity 1, at OOOrpm
1 37~245kPa {1.4~2.5kg/cnf}
at 3,000rpm
]\
/]
:
451 ~530kPa
{ 4.6~5.4kg / ]
cnf} 6. Install the oil pressure switch .
(1) Oil pressure switch thread and cylinder
Clean the switch mounting part of the durlock .
(2) Apply a pound (switch) to the threads of the oil breather switch.
Apply Rebond 2403) and install.
[]£HJ {1 40 1 3.7 3.9N•m
40kg cm}
7. Install the engine under cover left.
C-45
Cooling system
5 Cooling device
5-1 Thermostat removal and installation

1. Noise •When the coolant is hot, remove the radiator cap, water valve and drain plug.
Do not.
ÿ
2
| T: 19.o{195} |
ÿ Hose ÿ water outlet

ÿ Outlet ÿ Water w/ thermostat
ÿ Gasket water outlet *: Non-reusable parts
ÿ
Unit: N•m {kg•cm f

ÿ Thermostat
SKI E2078
5-1-3 Inspection
(1) Visual inspection
1. With the valve completely closed at room temperature (20°C), the sub
Make sure the ring is idle.
2. Check the rubber ring for damage.
3. Are bypass valves and jiggle bins running smoothly ?
Check .
SK1 E2079
(2) Valve opening temperature check
1.Put the thermostat in the water and gradually increase the intensity,
Measure the degree of mixture at the beginning of the valve opening.
Humidity standard specification
82°C 1.5°C
string
88 Sat 1.5 ÿ
SKI E2080
C-46
Cooling system
2. Measure the amount of lift when the mixture is further increased.

wet distribution standard specification
8 nm or more at 95°C
® specifications
8 nm or more at 100 °C
SKIE2081

(Refer to C. 1-5 (page C- 2))
Garden • The cooling water adjusts the coolant concentration according to the minimum temperature of each place .
C-47
Cooling system
5-2 Removing and installing the water pump

1. Noisy week •When the cooling water is hot, remove the radiator cap, water valve and drain plug.
not.
.
Drain cooling water

(Refer to C. 3-1 ( page C-24 ))
/ Ro
ÿ
)
ÿ /
.... ÿPump Ay, water

....ÿ Gasket ÿ water pump
....ÿ Cushion
Unit: N•m {k9 • cm}
SKI E2082
5-2-3 Inspection
1. Check for deformation and damage.
2. Check if the rotor rotates smoothly by turning it by hand.
5-2-4 Installation
1. Clean the water pump mounting area.
2. ÿ Install the cushion , ÿ gasket, and ÿ water pump Ay.
around the time Use a new gasket.
( Im 1 9. 1 Sat 3. 8 N m {1 95 sat 39 kg • cm}
5 -2- 5 Work after installation

l. Install the timing belt.
C-48
Cooling system
5-3 Radiator removal and installation

ÿ torque wrench
SKI E216
1. When the cooling water is hot, remove the radiator cap, water valve and drain plug.
Do not remove.
2. Remove the front panel center cover SIA .

(Refer to Section F.3 (page F-9))
3. Remove the front bumper.
( Refer to F.5 (page F-12))
IT:8.0 1.
6 { 80 Ota [ ] /
/\
Five]
ÿ
| T:8.0 1 .6 {80 16} |
ÿBase S/A, spare wheel carrier

ÿ Connector (radiator fan )
ÿ Hose ÿ radiator inlet
ÿ Hose , radiator outlet
ÿ Radiator Ay, W/ Fan motor
ÿMotor Ay, fan w/ shroud
Unit: N m { kg cm }
SKI E2084

1. Install the front bumper .
( Refer to F.5 (page F-12))
2. Remove the front panel center cover S /A .
(Refer to Section F.3 (page F-9) )
C-49
Cooling system
5-4 Radiator fan inspection

4 Electrical test, thermometer
SK1 E2 l7
5-4-1 Functional check

.
1 Use , the current when the fan is rotating.
a tester to measure
ÿÿ To rotate smoothly.
10A or less B
5-4-2 Individual inspection

( 1 ) Radiator thermo control switch
Catch
Turn on the continuity of the radiator thermo - control switch.
examine be.
Wet • standard
87 Sat 3°C or less No continuity
92°C 3°C or higher Continuity
•Cold regions
93ÿ3ÿ or less No continuity SKI E2086
98°C 3°C or higher Continuity
C-50
Intake and exhaust system
6 Intake and exhaust system
6-1 Intake manifold gasket removal and installation

em •Do not remove the water hose when the cooling water is hot .
6-1-1 Preparations
ÿ torque wrench
SKIE218

1. If there is noise or the coolant is hot, remove the radiator cap, water valve and drain plug.
Do not remove.
.
Drain cooling water
. Remove the battery negative terminal.

.
2 3. Remove the fuel tank cap Ay and release the internal pressure of the fuel line.
ÿ Hose , air cleaner , No. l ÿ Pump Ay, fuel

....ÿ Wire Ay, accelerator ÿ Hose ÿ Water
ÿ Hose ÿ
Fuel ÿ Hose
ÿ Modulator Ay, EGR vacuum Room _ ÿ ÿ Manifold Ay, intake w / carburetor
ÿValve Ay, EGR ÿGasket ÿ Intake manifold
ÿ Bracket ÿ EGR vacuum modulator
SKI E2087
6-1---4 Main points of removal

1. Remove ÿ intake manifold Ay W/carburetor .
(1) Remove each connector , vacuum hose , etc.
C-51
(2) Remove the nut and remove the intake manifold Ay with the carburetor.

1. After installing ÿ accelerator control cable Ay and adjusting the free play of the accelerator pedal, tighten the nut
to the specified torque.
Humidity 1 ~ 4 nm (after engine warm-up)

1. Install the battery negative terminal.
. Inject cooling water.
2 (Refer to C. 1-5 (page C-2))
C-52
6-2 Removal and installation of exhaust manifold gasket

noise Do not work on the exhaust manifold while it is hot.
adventure Kiki
SKIE2111

1. Remove the exhaust pipe.
6-2-3 Removal and installation procedures
ÿ Hesara: One word three nira three

I
| T: 25.5 Sat 5.1 1260 Sat 5 ]
Must
ÿÿ Bracket ÿ engine mounting ÿ Front No.1 Left

ÿ ÿManifold Ay, Exhaust
.... ÿGasket , Exhaust manifold * : Non-reusable parts
Unit: N•m { kg•cm}
SKIE2088

1. Using a transmission jack, etc., mount the engine + transmission at the position shown in the figure on the right.
support the action .
SKIE2089
C-53
2. ÿEngine Mounting Front Left No. 1

After removing the racket, remove the exhaust manifold
Remove Ay.
(1) Engine Mounting Front Left No. 1 Bra
,
Separate the connection of the gasket and secure the drawing margin as shown in the right figure. `-
Remove the exhaust manifold Ay.
SK1 E2090

1. After cleaning the gasket mounting surfaces of the cylinder head and exhaust manifold, install a new ÿ exhaust.
Install the Soest manifold gasket.

1. Install an exhaust vibe.
(Refer to C. Section 6--3 (page C-55))
C-54
6-3 Removing and installing the exhaust pipe

Do not work while the exhaust pipe is hot.
4 Torque wrench
SKI E220
| T:24.5 5.9 {250 6
ÿ
f
favorite
ÿCover Ay, Engine Under

ÿDuct , air cleaner inlet
ÿ Duct ÿ
air inlet
ÿPipe Ay, Exhaust ÿ Front * : Non-reusable parts
exhaust pipe Unit: N•mjkg•cm}

ÿGasket ÿ
SKI E2091
C-55
Engine Ay
7 Engine Ay
7-1 Engine Ay removal and installation
Do not bring fire close to the fuel system when working on the fuel system.
•When removing the fuel hose , prevent the fuel from scattering.
•When the cooling water is hot, remove the radiator cap , water valve , drain plug , water
Do not remove the tar hose.
• Do not remove the drain plug when the oil is hot .
7-1 - 1 Preparations
shape letter for road
Model Product Name
s engine, sling device ENGINE, TRANSMISSION HOLD
s milk 09090-04010-000
T.
High mission jack
Banzai Co., Ltd. HMJ-450TW Engine removal and installation
tool
Iyasaka Co., Ltd. ML850
Fats andI Torque

Instrument oils Mission
wrench oil
SKIE221

1. Remove the fuel tank cap and release the internal pressure of the fuel line. 2. .
Disconnect the battery negative terminal.
4. Noisy week •When the cooling water is hot, remove the radiator cap, water valve and drain plug.
Good things.
.
Drain cooling water
5. National Seal • Do not remove the drain plug when the oil is hot .
Drain the transmission oil.
6. Remove the propeller shaft.
(Refer to D. 3-1 (page D-31))
7. Remove the exhaust vibrator.
C-56
Machine Translated by Google Engine Ay
ÿ
/ `'
Koji: 41 \7 4 { 42 b
two {`/ / ÿ: 58 .8 0.8 {600 king m town

ÿ
Unit: N•mjkg•cm}
ÿ Baltic ÿ V (for air conditioner compressor ) ÿ Hose heater

ÿ
... ÿ Compressor Ay, WÿMagnet clutch ÿ Cable Ay, clutch release

ÿHose ÿ Air cleaner ventilationÿ No 1 ÿ Cable , transmission control shift
ÿHose ...ÿ ÿ ÿ Cable , transmission control select
Wire Ay, Accelerator ( 20) Harnesses , connectors ( related to starter manual transmission)
ÿ
ÿHose fuel (main)

ÿ
ÿCable Ay , speedometer drive
ÿ Hose ÿ Fuel ( return ) ÿ Hose (for distributor ventilation: 2)
ÿVacuum hoses (engine related) ÿÿ Bracket S/A, engine mounting front light
ÿ Cord coil resistive
ÿ ÿ Starter Ay
ÿ Harness connectors (engine related)
ÿ ÿCover Clutch Housing Under
ÿ
ÿ Hose (for brake booster ) ® Transmission Ay, manual

ÿ Cover left ÿ engine under ÿ ÿ Bracket ÿ ÿ engine mounting ÿ Front No. 1 Left
ÿ Cover ÿ engine under Bracket, engine mounting ÿ Bracket Air conditioner ÿ light
ÿ Hose ÿ water inlet compressor ÿ
ÿ Hose ÿ water outlet ÿEngine Ay
SKI E2092
C-57
Engine Ay
7-1-4 Points of removal

Garden • When disconnecting wiring, gently remove it by holding the connector .
1. Remove the ÿ Compressor Ay Wise Magnet Clutch and hang it on the .
body. 2. ÿ Engine Mounting Front Light Bracket
Remove the S/A as follows .
(1) Use a mission jack, etc. to lift the engine + mission Ay.
Support it as shown in the right figure.
(2) Engine mounting front light bracket

t S/A, engine mounting
Separate the motor from the ,body Engine + Transmitter
Ay from the vehicle.
(3) , Remove the nut and remove the engine mounting
Remove the bolt front light bracket S /A .
1. ÿInstall the manual transmission Ay. (CDs
Garden • The bolt shown in the right figure uses a bolt with a sealant.
Therefore, use new bolts with sealant.
be used.
:]
SKI E2094
2. After installing ÿ accelerator cable Ay,

Adjust the pedal free play .
Humidity 1 to 4 (after engine warm-up)

1. Install the exhaust pipe.
2. Install the propeller shaft.
3. Fill with transmission oil.
.
4. Perform clutch adjustment
5. Jack down the vehicle 6. Adjust .
the tension of the air conditioner belt .
Standard value (pushing force: 10 kg)
When replacing a new belt When readjusting a belt
Immediately after assembly 6.0~7.0mm 7.5~8.5mm

|
after driving 8.5~12.0mm
SKI E225
C-58
Engine Ay

C-59
fuel supply
8 Fuel supply
8-1 F Removal and installationof fuel tank
noise Keep fire away while working.
8-1-1 Preparations
Kiki
Say
SKIE222

1. Remove the fuel tank cap Ay and release the internal pressure of the fuel .
line. 2. Remove the battery negative terminal.
3. National Seal •Do work to prevent fuel scattering.
Drain the fuel as .
follows ( ) 1 End of the main side fuel hose ( Fuel tube
side) with tape .
for seal )
(2) Remove the main side fuel hose and install the manual pump.
into the tube of the
(3) After removing the fuel tank cap Ay, manually wrap with tape
.
Operate the pump and drain the gasoline
SKIE2105
Four
Kuchito Sat 1.75 {32.5 Sat 17.5}

IIT: 2.25 0.75 Sat
{22.5
17.5}
Mouth: Ashizo
Hatake 'Roni: ' : Tsu >/
Gen
ÿÿ Hose ÿ Fuel tank sub, inlet

ÿÿ Hose ÿ fuel , main
Sunwang 2! 45 { 1 :
ÿÿ Hose ÿ fuel return
ÿÿ Hose ÿ Fuel (tank to canister )
ÿÿ Hose ÿ Fuel , Nol
ÿ Connector ( for sender gauge)
ÿÿ Tank Ay, Fuel
ÿTube S/A, fuel tank vent
Unit: N m { kg cm }
ÿ Gauge Ay, fuel sender
SKI E2096
C-60
fuel supply
8-1-4
Inspection (1) Fuel tank level gauge S/A (See G.
3-1 (page G-5))

ÿInstall the fuel tank S/A. (1) Install the
fuel tank S/A and tighten the bolts to the specified torque. (2) Remove
the hoses (main, return , evaporator, breather) .
attach.
Fix •Install
each hose as shown in the figure on
the right. (3) Attach the connectors for the fuel pump
and fuel level gauge .
SKI E2097
2. ÿ Attach the fuel tank sub inlet hose and tighten the
hose clamp. Around •Tighten the hose clamp until
it touches the spacer as shown in the right figure.
spacer
SKI E2098

C-61
fuel supply
8-2 Fuel pump removal and installation

.
• Carry out work to prevent fuel scattering

1. Remove the fuel tank cap 2. , Relieve pressure in fuel line .
Remove the service hole cover (front side).
®Rhinoceros _
Flash
mouth
...ÿ hose ÿ Fuel (main)
...ÿ hose ÿ Fuel ( return )
...ÿ hose ÿ Fuel -L pump - carburetor )
ÿ Hose ÿ Vacuum _
ÿ Pump Ay, fuel

...ÿ Insulator S/A, Fuser l pump * : Non-reusable parts
...ÿ Rod ÿ Fu pump push Unit: N•m {kg•cm}
SK1 E20H

1. Remove ÿ fuel pump insulator and ÿ fuel pump bush rod.
around the time Do not drop the fuel pump pushrod .
8-2--4 Points of installation

1. Install a new ÿ fuel pump insulator and ÿ fuel pump bush rod.
Trouble • Do not drop the fuel pump pushrod .
2. ÿFuel hose (pump to carburetor ), ÿFuel hose ( return ), ÿFuel hose
(main).
C-62
fuel supply
Fuel filter removal 8-3 , mounting

•Prevent fuel from scattering.

1. Release the fuel pressure in .
.
the following manner. 2. Remove the fuel tank cap Ay and release the internal pressure of the fuel line.
and
ÿ' 55
ÿ Hose ÿ Fuel (tank side)

ÿ Hose ÿ Fuel (pump side)
ÿ Filter Ay, Fuel
SKIE2101
C-63
fuel supply
8-4 Removing and installing the caplet

National Seal•Keep fire away during work.
supplies
blood
ÿ8-4-1 SKIE223

1. Remove the fuel tank cap and release the internal pressure of the fuel line. .
2. Remove the battery • terminal.
3. When the cooling water is hot, remove the radiator cap, water valve and drain plug.
not.
Drain cooling water .
ÿ ÿ Hose
ÿ Hose
ÿ
ÿ
air cleaner
Ventilation
ÿÿ Wire Ay, Accelerator
ÿ ÿPipe S/A, fuel , No1
ÿ ÿHose ÿ Water
`
ÿ No1 ÿVacuum hoses
ÿ Connector ( for fuel cut solenoid )
ÿ ÿ Hose
ÿ ÿInsulator
ÿ
ÿÿ Carburetor Ay
Fuel
ÿ carburetor heat
Unit: N•m { kg•cm )
SKIE2102

1. ÿ Remove the air cleaner hose .
Trouble • Cover the captor air horn with tape to prevent foreign matter from entering .
C-64
fuel supply
2. Flush ÿFuel No. 1 Vibe S/A from the carburetor.

Disconnect the fuel hose while it is connected.
3. Installation •When the cooling water is hot, remove the water hose .
Never.
•Keep fire away.
• Perform work to prevent fuel scattering.
ÿ Remove the water hose.
4. Noisy and snowy •Work to prevent fuel from scattering.
ÿFuel hose ( fuel pump - carburetor 'What ,
' ' SK9 E29 03
between terminals).
1. Install the new carburetor heat insulator as shown in the right figure.
Orientation and align the carburetor Ay mounting nut
Tighten to the specified torque.
intake
Manifold side
SK, E2, 04
2. Connect the accelerator control cable Ay to the cab

Push it all the way into the U-shaped groove of the letter side bracket,
Bracket nut Eliminate looseness between the whirl-stop and the nut
Tighten the nut while holding the cable firmly in place.
Kick.

Approximately •Make sure there are no mistakes in the assembly of each switch and vacuum hose .
(Refer to C. 9-2-2 (page C-68))
1 . Attach the battery • terminal.
3. Adjust the free play of the accelerator pedal.
Wet 1 ~ 4 rnn (after engine warm up)
C-65
Exhaust gas purification device
9 Exhaust gas purification device

9-1 Exhaust gas cleaning equipment list
engine type
Device name Method Component part Purpose function
EF-CK
Air-fuel ratio controller Fixed venturi [ 1 ] Fixed venturi carburetor Reduce CO , HC, NOx
ÿ
Exhaust gas Back pressure control method [l] EGR valve • NOx reduction
Recirculation device [2] Operation control device EGR according to warm-up state and retarded state
ÿ
•Pressure regulating valve ( modulator )
BVSV
Ignition timing Single vacuum control [l] Distributor control device • Reduced N0x
Control method (Centrifugal, negative Appropriate ignition timing control according to
ÿ
pressure type) [2] Operation control operating conditions is performed.
device •Vacuum pressure delay valve (VTV)
Deceleration control device Throttle position [l] Throttle positioner Reduction of CO and HC
One method [2] Actuation control device •Vacuum When decelerating. Sudden closing of throttle valve
pressure delay valve (VTV) to prevent this and improve combustion.
Auxiliary control device Choke breaker [1] choke breaker • Reduction of CO and HC, improvement of usability
One [2] Operation control Controls the opening of the choke valve ÿ
method (automatic choke ) device •Aperture (Jet) according to the warm-up state of the engine .
Fuel evaporative gas exhaust canister method [1] Charcoal canister Fuel evaporative gas emission prevention
ÿ
device
Blow - by gas closed [ l] Blow -by hose [2] Orifice • Reduction of CO and HC
Original equipment Reburn the blowby gas ÿ
Prevent CO and HC emissions.
SKIE301
C-66
pressure crossing
X Haruko tvX Haruka f=K>XT
T.
map
map
Stagnation
Tsuji N Zhe
C-67
9-2-2 Exhaust gas purification piping diagram
one_
SKIE3002
C-68
9-3 Exhaust gas recirculation device

9-3-1 Back pressure control method
(1) Preparations
Kozuki Vacuum Gauge, Mighty Bag

SKIE302
(2) System diagram
EGR valve
SKIE3003
(3) Functional inspection

1. Remove the vacuum hose from the Q port of the modulator and
Connect vacuum gauge via 3-way .
2. When the engine is cold (cooling water overflow 45°C or less), idling state
The needle of the vacuum gauge does not swing at 4, OOOrpm
When racing is repeated, almost no negative pressure is applied.
Confirm that
3. After engine warm-up (cooling water overflow 70°C or more), idling state
The needle of the vacuum gauge does not swing at 4,000rpm .
Confirm that negative pressure is , around 100 dish Hg each time
applied when racing is repeated.
C-69
(4) Unit inspection

ÿ EGR valve
ÿ Confidential inspection
1. When a negative pressure of approximately 400 mmHg is applied to the diaphragm chamber ,the pointer
should be stable.
ÿ Ventilation inspection
1. Check for ventilation between ® and ® with negative pressure applied to the diaphragm chamber.
wetness • Negative pressure of 50 surface Hg or less
®~® No ventilation
• Negative pressure 1 50 beat Hg or more
®~® with ventilation
ÿ Modulator
1. Connect the mighty back to the P port and touch the Q port with your finger.
Confirm that the negative pressure is not maintained when negative ,
pressure is applied with a mighty bag in a crushed state .
2. While blowing air through the back pressure port ,

Confirm that the negative pressure is maintained when the negative pressure is applied with the hook.
do.
3. Make sure it stops when you stop blowing through , negative pressure is low
the back pressure port .

SKI E3008
ÿ BVSV 1. After
Ha
being submerged in water for at least 2 minutes with the following flooding, ventilate between ports .
Check for presence.
water temperature Port-to-port ventilation
45°C or higher ÿ
70°C or higher X
SKI E303
SKIE3009
C-70
9-4 Ignition timing control device

9-4-1 Single vacuum type control method
(1) Prepared items
Souichi Vacuum Gauge , Mighty Bag

SKI E302
(2) System diagram
Distributor
combustion chamber
SKIE3010
1. Vacuum via 3-way to distributor Distributor

Connect the gauge.
2. At idle rotation, the needle of the vacuum gauge is 0 .
I wish I had.
3. As the engine speed is increased, the
You just have to perceive the negative pressure.
VTVs
SKl E30''
(4) Unit inspection

ÿ Vacuum controller
ÿ Operation check
1. Connect a mighty bag to the diaphragm chamber to apply negative pressure.
When applied, the breaker plate is sucked, creating negative pressure
When set to 0, the breaker plate returns quickly
Just do it.
SKI E30l2
• Diaphragm chamber air tightness check

1. The pointer should be stable when a negative pressure of 500mmHg is applied.
C-71
9-5 Deceleration control device

9-5-1 Throttle opening control device
(1) Prepared items
4 Vacuum gauge, mighty bag

SKI E302
(2) System diagram
Throttle positioner
TP port
VTVs
SKIE30l3
1. Warm up the engine. (Fan motor operates once

to)
2. Vacuum through 3- way to throttle body
Install the muguage .
3. 4, When racing OOOrpm , the vacuum game
gauge pointer returns to 0 and returns to manifold vacuum
thing.
(4) Individual inspection
ÿ Actuator
1. A mighty bag was connected and a negative pressure of 400 plate Hg was applied.
when the shaft is pulled.

2. Next time the negative pressure is released, the shaft should return quickly.
do 'o
SK1 E3015
9-6 auxiliary controller

9-6-1 Choke breaker method
(1) Prepared items
Four Mighty Bucks

SKt E306
(2) System diagram
choke valve
SK1E3016
1. Remove the air cleaner hose .

2. Before starting the engine, the choke valve must be fully closed.
to confirm.
3. Unplug the hose of the choke breaker and insert your finger into the mouth of the hose.
and start the engine.

At this time, check that negative pressure is acting on the hose .
C-73
4. When hose is connected to choke breaker

, Cho Cho
Check that the lock breaker rod is pulled and the link moves.
inspect.
(4) Unit inspection

ÿ Choke breaker
,
is stable and the lot is pulled when negative pressure is applied.

Make sure the link works.
SKI E3020
ÿ Jet
1. Hold one side with your finger and raise the negative pressure to 400 mmHg.
Make sure the needle is stable 2. .
Remove your finger from the state indicated by J: and make sure that the negative pressure is released slowly.
When.
C-74
9-7 Fuel evaporative emission control device

9-7-1 Canister one method
(1) System diagram
ffff IIIIIII / 10,000 / fffffffffff

Combustion chamber <= two /
Carburetor
Charcoal canister
fuel tank
SKI E3022
(2) Unit inspection

ÿ Charcoal canister
1. Check the charcoal canister for dents or other damage.
inspect.
2. Connect Mighty Buds to each port. , check valve
Check the ventilation of the drive.
SEIK3023
C-75
ignition device
1 0 ignition device
1 0-1 preparations
Four electrical testers, thickness gauges

SKI E307
10-2 System diagram
Engine (15A) Distributor

r I-----------_---l
ignisi :
"---l ||
I
ÿ11ÿÿ——1_L
I
I
coil I
I
bag
Te
Lee
---:Up ||
Up ||
twenty three
Decree ÿ'
i'-----------------_J i ordinance_
ÿÿ —— ÿÿ
SKI E3025
1 0-3 Ignition Coil

1 0-3-1 Ignition coil inspection
(1) Primary voltage check
ÿ
1. Turn the IG switch "ON".
2. Harness side terminal ÿ to .
body ground for measuring the following voltage
wet battery voltage
SKI E3026
(2) Primary coil resistance measurement
1. Turn the IG switch to "OFF".

.
2. Measure the resistance between the following terminals .
1.0 sat 0.10
Ignition coil terminal ÿÿÿ
wetness
C-76
ignition device
(3) Secondary coil resistance

measurement 1. Turn the IG switch to
"OFF". 2. Measure the resistance between
the following terminals. Ignition coil terminal ÿ
to high voltage 1 3. 4 SatHumidity

terminal 2. 0kQ
1 0--4 spark plug 1

0--4-1 spark plug inspection
1. Make sure you are using the specified
plug. 2. Check electrode gaps.
Souichi Electrical Tester , Thickness gauge

SKI E307
1 0-5 Distributor 1 0-5-1 Distributor

inspection (1) Air gap inspection 1. Signal
generator and With the signal rotor projections
facing each other , check the clearance using a thickness
gauge. wetness
0.2 ~ o.41t111
Adjust if it deviates from the standard.
SKI E3029
(2) Resistive cord inspection 1. Measure

resistive cord resistance. Wet 25kQ/piece
or less
2. Install resistive cord
Install so that there is no contact between resistip cords and hoses.
C-77
starting device
1 1 Starter
1 1 -1 Preparations
Kozuki electrical tester, lead wire (thick), battery

SKI E308
I
1 1-2 System diagram
IG switch (ST)
F/L 0.85sq
--__-------ÿ
"___------------------- l
I
I
I
I
I
I |
bag
-'
I
I
Te ||
I |
I _
Lee I
Il
I
'(Upper T I
I
| I
Il
I
soil one I
Il
I
I
I
I
death
ÿ _-- - - L. --__-------------------- __..J
I
I starter
SKI E3030
C-78
starting device
1 1-3 Starter removal and installation

1 1-3-1 Removal and installation procedure
Otsuchi 8.0 {400 Shi 8 Shout
SK1 E3031
1 1-3-2 Work before removal

1. Remove the battery C) terminal.
1 1 -3-3 Work after installation

1. Attach the battery C) terminal.
1 1-4 Inspection
1 1-4-1 Around the starter•
Each inspection is done in a short time (3 to 5 seconds).
SK1 E3032
C-79
starting device
(1) Pull-in
inspection•With
.
the lead wire of the magnet switch
removed Confirm that the pinion
gear pops out when the body is grounded.
SKI E3033
(2) Maintenance inspection of the holding coil 1.

When the wiring to the C terminal is removed from the
pull-in inspection state, confirm that the pinion gear
remains protruded.
SKI E3034
(3) Plunger return check 1.
Check that the pinion gear returns when the starter
body ground is removed from the holding
coil maintenance check.
SKI E3035
(4) No-load test
shock] • Use thick lead wires because a large current 30 terminals
flows during the test . (1) Fix the starter with

a vise or the like. (2) Connect the cable and tester as
shown. (At this time, do not wire to terminal ÿ) (3)
Connect terminal ÿ, and read the current value when
the ammeter reading stabilizes. m ,. A or less
SKI E3036
C-80
charging device
1 2 Charger
1 2-1 Preparations
4 Electrical tester I
SKI E309
1 2-2 System diagram
B " ---________----------------------- _
l
engine I
(15A)
I| I1 _
(IG2) IG | : |
IG - :
"ÿ------- :B
| 1 11
I Ir---,---,---y-- II I I ""I I I
I!|
1l _
l lll 1 Pl l lll ÿ1 |
I I I I :i I I Jin 1
||
I I Il
stomach
I I I
I I
bag
I I I
Te I I
I I I|
IL- I
I I
T. bag Lee I
Te Shhh! ÿ ÿ ----------- ---------------"

indicator—
Alternator
Lee
Char
A IC regulator
Top T|-
hmm
The -=
pu
SKI E3037
1 2-3 On-board inspection
1 2-3-1 Pre-inspection
1 . Ba Battery specific gravity check
wetness 1.25 ~ 1.278 (liquid temperature 20ÿ)
2. Check the connection status of the battery terminal .

3. Check V-belt deflection.
4. Fuse check.
5. Wiring condition check.
.
6. Check for abnormal noise from the alternator while the engine is running.
C-81
charging device
1 2-3-2 No-load test

1. As shown in the diagram on the right, slowly .
2. increase the engine speed to 2, OOOrpm, connect the tester , and check the voltage and
Measure the current.

wetness 13.6~14.4V (25°C)
10A or less
1 2-3-3 Load test

1. From the no-load test state , turn on the headlamp high beam and turn the heater blower switch to high.
Ru .
.
2. Measure the current when the engine speed is 2, OOOrpm
Wet 30A or more
[Reference] •Even if the current is below the reference current, the current will be small when the battery is fully charged.
Replace with a discharged battery , or increase the load (measure , Defogger , etc.)
.
the hazard rate).
1 2-4 Alternator removal, 1 2-4-1 Mounting

Pre-removal work
1. Remove the battery • terminal.
2. Remove the service hole cover.
C-82
charging device
1 2--4-2 Removal and installation procedure
ÿ`
ÿ
ÿ
` ///
Loaf: 39.0 8.o {400 80} I
ÿ Belt ÿ Belt ÿ V (for air conditioner)

ÿ Bar ÿ ÿ V (for alternator )
Alternatorÿ Adjusting Unit: N•m{kg•cm}
SKI E3039
1 2-4-3 Work after installation

1. Adjust the V-belt tension .
(Refer to C.1-9 (page C-4) )
2. Attach the service hole cover .
3. Attach the battery • terminal.
C-83
clutch
1 clutch
1-1 Clutch pedal adjustment
Jidota
1-1-1 Clutch pedal free play adjustment

1. Pull the clutch outer cable toward the front of the vehicle and
The razuchi release bearing is in the die of the clutch cover.
Stop at the position where it hits the diaphragm spring .
2. In the above state, turn the adjusting screw so that the adjusting screw and grommet
Adjust so that the gap (dimension ® in the figure on the right) is 3.5 to 5.0 mm.
Check that the free play .

3. Align the projection of the grommet with the nearest groove of the adjustment screw and adjust.
SKI KIOOI
.
of the clutch pedal that secures the adjustment screw is within the standard value.
Four.
moist _ clutch pedal play

1 5~2511111
1-2 Remove the clutch pedal, Mounting
3. Amix MP Grease
SKI KIOI
Amix MP Grease
''
Press 2 3 .5 {185 Sat 3 Shout
ÿCable Ay , clutch release

ÿ Washer ÿ ÿ plate
Bush
....ÿ Pedal S/A, Clutch
ÿ Shaft ÿ ÿ pedal
Bush
ÿ Spring ÿ
torsion
SK1 K1002
D-1
clutch
Amix MP
1. ÿ Inner surface of clutch pedal SIA and clutch release Grease application
Connection with cable and inside of ÿ torsion spring

Apply Amix MP Grease to the surface .
/
Trouble • Grease adheres to the pedal shaft thread. O(

Be careful not to
oath
SKI KI003
1-2---4 Work after installation

1. Adjust the free play of the clutch pedal.
(Refer to D. 1 -1 ( page D -1))
1-3 Remove and install the clutch cable

1-3-1 Preparations
Obi Amix MP Grease

SKIKI02
He Lr: 5.4 Sat 1 .5 {55 1 5t |

ÿ
Heart ` ` ÿÿ ÿ ÿ
....ÿ Cover clutch housing

ÿ
.... ÿCable Ay, Clutch release

ÿPlate Plate
ÿ Washer ÿ
ÿ
ÿ
release fork set
ÿ•
B
Bush
SK1K1004
D-2
clutch
1-3-3 Inspection
1. The inner cable of the clutch release cable Ay
2. Check that each part of the .
clutch release cable Ay is worn, damaged, or worn .
.
Check for deformation, cracks, etc.
SKIKI005

1. Pull ÿ clutch release cable Ay into the room,
Apply Amix MP grease to the end of the cable and attach ,
it to the clutch pedal together with the ÿ plate washer
and ÿ bush.
to the wall.
2. ÿ Release forkset plate to transmitter
and tighten the two bolts to the specified torque.
be.
3. ÿ Connect the clutch release cable Ay to the clutch release cable .
Attach to fork. SK1K1006
Trouble • Remember to install the clamp.

4. Adjust the free play of the clutch pedal.
Five . ÿInstall the clutch housing cover .
Trouble • Orient the clutch housing cover as shown in the figure on the right.
Install.
D-3
clutch
1-4 Clutch installation/removal
1 -4 - 1 Preparations
09210-87701-000
Flywheel detent
HOLDER, FLYWHEEL
s 09301-87501-000 clutch disc, clutch

tool, clutch guide Installing the cover
s
09302-87701-000
clutch cover diaphragm
Gauge, Clutch Diaphragm
T. Spring misalignment correction
Spring Height No.4
/
09333-00013-000
clutch cover diaphragm
Aligner , clutch diaphragm
Spring misalignment correction
spring ring
Oil Amix EP1Grease

Instrument Dial gauge, Vernier caliper , Thickness gauge
SKIKI 03
D-4
clutch
1-4 2 Removal - Pre-work
1. Remove the transmission Ay from the vehicle.
1--4 3 Removal - , Installation procedure
Amix EP Grease
18. 2 Sat 3.5{185 Sat year[ |
/
]
Amix EP Grease
...... ÿCover clutch

Ay, ......ÿDisc Ay, Clutch ...ÿHub
ÿ
Clutch
Ay, ... ÿClip , Release release bearing
Bearing
Hub bu
...ÿ Fork ÿ ÿ Clutch release
Spring ... ÿ Release fork anti - rattle Unit: N•mj kg•cm}
ÿ
Support ÿ release fork

SK1KI008

1. Use SST to stop the ring gear from rotating and tighten the bolt.
Remove the 6 screws, ÿ clutch cover Ay and ÿ clutch
Remove disk Ay.
snow 0921 0-87701-000
1-4-5 Inspection
1. Check flywheel runout 0 .
.10nm
D-5
clutch
2. Check the clutch disc Ay for wear and run-out.
Abrasion limit 0.3nm
Lateral runout limit 1.011111
3. Sliding part of clutch release bearing hub S/A

contact surface with the switch cover ) and when the pressure is
In addition, when pressed in the direction of rotation, an abnormal response or pull
.
Check if there is any hanging
tKIOI I
Clutch disc
SKIKIOl2
4. Damage to each part of the clutch release bearing hub S/A,

Check for wear .

1. ÿClutch release fork or ÿClutch release
Amix EP is applied to the sliding surface of the bearing hub Ay.
apply wreath .
Grease application
SKI KI Ol4
2 ÿRelease bearing hub clip to ÿClutch lever

Attaches to Lees Fork .
Garden • The release bearing hap clip is shown on the right.
Assemble in the direction of
ÿ ... fork
Clip assembly direction
SKI KIOl5
D-6
clutch
one
centre Oh
ÿ
po Attach
turret
the
zubi
attached rulesfixed child hand .
9, nz
to ÿ S
E 34
ÿ
one
o ÿ
nine SaxaPo
Ichigo-
Ua
Total sliding surface lap Jimi _ guk
l'
zu phantom fu paint
to clothvinegar Ru °
5. Apply Amix EP grease to the entire inner circumference

r\\ÿ|/j
\\J
ÿ Bÿ ÿ
of the clutch release bearing hub, andfork

release attach
Ay ÿtoclutch
the
transmission. attach.
6. Apply a thin coat of Amix EP grease to the

splines of the clutch
. disc. Apply a thin layer Grease application
of greasenot
to the
protrude.
flywheel
Wetside
0 so that it does
Transmission side
. 2 grams
(clutch cover side)
SK1K101 8
7. Using SST, center ÿ clutch disc Ay and install it
to the flywheel . 09301 -87501 - 000 Be careful
not to mistake
clutch disc
theAy.
installation direction of the
8. Attach ÿ clutch cover Ay by aligning it with the dowel pins

(three places) of the flywheel , use SST to stop the
flywheel from rotating, and tighten the bolts. Tighten the 6
bolts to the specified torque. 0 921 0-87701 -000•Tighten
the bolts in the order shown on the right.
.
D-7
clutch
1. Use SST to check for unevenness in the height of the
diaphragm spring. Snow 09302-87701-000 direct. 2. If
the above inspection
check exceeds the limit, use SST to
the height.
0.711111
Fix irregularities.
Snow 09 333-0001
3-000 3. Install
transmission Ay to vehicle.
(Refer to D. 2-2 (page D-10) )
D-8
manual transmission
2 manual transmission
2-1 Manual Transmission Identification
(Reference) •An identification label is pasted on the left side of the mission case.
2 1 5 61 T 1 77 A ÿ |
SKIKI022
D-9
manual transmission
2-2 Manual transmission removal and installation
Amix Gya Oil 75W-85 (GL-3) Oil I

Amix EP Grease
SK IKI04

1. Remove the • terminal of the battery .
2. Lift up the vehicle.
3. Remove drain plug and gasket , Trance
Drain transmission oil .
4. Remove the propeller shaft.
Five . Engine harness No. at extension housing
2 Remove the terminal.
D-10
manual transmission
this 3_._ 5 {l 85 35} 1
ÿ®--Wang 39.0 Shi 8.0 {4 three
| T: 36.8 Sat 7.4 {375 Sat 75 } |

[T: 1 8.2 3.5 {185 four shouts
111\\1
ÿ--Toro | T:24 6 {25ÿ
ÿ
[ T: 36 .8 Sat 7 .4 { 375 Shi 7

ÿ
Amix EP Grease
T: 58.8 Sat 9 ÿ {600 Sat
Three mouths
ÿ
garden

ÿCable Ay, shift
ÿCable Ay, select
....... 4 Cover ÿ Clutch housing
.... ÿCable Ay, Clutch release
ÿPlate release fork set
ÿ
ÿ Starter Ay
ÿ ÿ Park Latch Housing Under
ÿ
,.. ÿ Bracket Transmission control cable

ÿ
,.. ÿ Bracket engine mounting, rear

ÿ
ÿInsulator S/A, engine mounting, rear *: Non-reusable parts

....ÿ Transmission Ay Unit: N•m {kg•cm}
SKIKI024
D -11
manual transmission
1. From the service hall in the room , ÿTransmission Ay
and two engine mounting bolts and a plate nut
Remove one.
2. From the service hall in the room , ÿ Clutch housing

Undercover and clutch housing mounting bolts
Remove one
3. Using a transmission jack, etc., remove the ÿ transmission
Supporting N Ay.
4. Remove the two bolts and remove the ÿ transmission control

cable bracket.
SKIKl027
5. (10) Removal of engine mounting rear bracket

death
(1) Exhaust muffler Ay and exhaust pipes

Remove the mounting bolt of the tee.
(2) Engine mounting rear bracket and engine

Installation of mounting insulator S/ A
1 mounting bolt and transmission case mounting bolt
Remove the 2 screws and install ÿEngine mounting rear
Remove racket.
: Double rent 1029
D-12
manual transmission
6. ÿTransmission Ay and engine and stiffener RH
Remove the two mounting bolts for each.
7. Remove the 3 mounting bolts and attach ÿ Clutch housing

Remove the ground under cover .
8. Remove ÿTransmission Ay from the vehicle. the law of nature

1 . Remove the sealant from the bolt hole on the engine side and clean it .
do.
SKI KI032
2. Inbut shaft subline outer circumference (thin) and tooth groove

(about 1/3 of the depth) with Amix EP grease.
be.
/
/
SKIKI033
3. Installing the clutch housing under cover

(1) Using a transmission jack, etc.,
ÿ Clutch housing
|
Assemble the ground under cover from the bottom, and temporarily
attach the three ports.
ÿ SKIKIO34
D-13
manual transmission
[Reference] • Temporarily tighten the two mounting
bolts between the engine and the
.
transmission so that the temporarily
With sealant
assembled
Assemble.
transmission Ay does not come off .
(2) Install the clutch housing and the clutch housing

undercover mounting bolt from the interior service
hole , and tighten to the specified torque. Next,
tighten the three temporarily attached bolts to the specified torque.
4. ÿ Transmission Ay and two engine mounting bolts

(the bolts temporarily attached earlier) and two
.
mounting bolts for the stiffener plate RH Specified
torque Tighten with
SKIKI037
5. From the service hole in the room, tighten ÿ
transmission Ay and the two engine mounting
bolts and one plate nut to the specified torque.
6. ÿ Attach
clutch
therelease
clutch release
fork and cable
adjustAy
thetofree
the
.
play of the clutch pedal. be.
2-2-6 Work after assembly .

1 Install the engine No. 2 terminal.
2. Install propeller shaft Ay.
D-14
manual transmission
3. Install a new gasket and set the drain plug
After tightening with torque, remove the transmitter from the filler plug.
Inject the specified amount of motion oil.
wetness From bottom of filler plug hole
be between 0 and 5 nm
Sonoguchi Sonoguchi Amix Gear Oil 75W-85 (GL-3)
Total capacity 1.1 9
Around 39.2 Sat 9.8 N m 4. Lift {400 1()()kg • cm}

down the vehicle.
Five . Connect the ÿ terminal of the battery.
D-15
manual transmission
2-3 Removing and installing the extension housing oil seal
|\ shape letter Model Product Name for road
s / 09308-00010-000
s
blur, oil seal
Remove oil seal
09309-87201-000
T.
_ Rib racer, transmission oil seal installation
Bearing
Amix MP Grease
Fats and oils
Amix Gya Oil 75W-85(GL-3)

SKIKI05
D-16
manual transmission
2. Remove the drain plug and gasket, and drain the transmission oil. 3. .
Remove the propeller shaft Ay.
(Refer to D. 3-1 ( page D-31))
2-3-3 Removal , installation instructions
Amix MP Grease
....(1) Seal , type T oil

SKI KI040

1. Using SST, remove the ÿ type T oil seal.
vinegar.
Snow 09308-0001 0-000
D-17
manual transmission
After applying Amix MP grease to the entire
circumference of the rib of a new ÿ type T oil seal ,
use SST. to install. ÿ
09309-87201-000
2-3-6 Work after

installation 1. Install the brobera shaft Ay.
(Refer to Section D. 3-1 (page
D-31)) 2. Install a new gasket, tighten the drain plug to the specified torque, and remove the drain plug from the filler plug.
Inject the specified amount of
transmission
0 andoil.
5 11111
It mustfrom
be between
the
bottom of the damper
plug hole . . Lower the vehicle.
{400 1 00kg • crn}
D-18
manual transmission
2-4 Removal and installation of speedometer driven ring gear
09201-60011-000
speed make shaft
s Remover & Replacer , Valve
Installation of sleeve and oil seal
guide bush
s
09921-00010-000 speedometer shaft _
T ÿ=ÿ konini) Tool, spring tension Removal of sleeve and oil seal
SKI K106
D-19
manual transmission
''ÿ.ÿ — K ^
application of application oil

ÿPlate speedometer sleeve lock
ÿ
ÿ Gear , speedometer driven

ÿ Ring, 0
.......ÿ Seal Type V oil
ÿ * : Non-reusable parts
ÿSleeve , speedometer shaft Unit: N•m {kg•cm}
SKIKI048
2-4-3 Points of Removal

. ÿBefore removing the Type V oil seal , 1 , ÿ SST
SST
Insert and mark the speedometer shaft sleeve ,
Please add , Use it as a reference when installing.
09201-6001 1-000
Sktkto“
2. Using SST, ÿ speedometer shaft

Remove the ÿ Type V oil seal from the rib.
SST
rn!] 09921 -0001 0-000
D-20
manual transmission
2-4-4 Inspection
1. Speedometer driven gear shaft and gear
2. Check the speedometer shaft .
.
sleeve for damage.
Inspection to
Loss: wear and tear, damage
SKIKI046
2-4-5 Identification of speedometer gear identification mark

identification color
(MB)
Number of drive gear teeth (identification) 4 (resin material color)
speed
Meter Gya I Number of teeth of driven gear (identification) House (MB (dark brown))
SKIKI07
`[9 o fee color)
<
<Drive Ga> SKIKI047
2--4-6 Points of installation

1. Using SST , , ÿ Speedometer shaft
SST
install a new ÿ Type V oil seal on the reed.
be.
Darkness 09201-6001 1-000
[Reference] • Refer to the mark you made when removing the
insert the seal into the sleeve .
oil seal
2-4-7 Inspection after installation

1. Check if the speedometer works properly .
D-2 1
manual transmission
2-5 Removal and installation of backup lamp switch Ay
2-5-1 Preparations
Kozuki Tester
SKIKIOI
Pressure 9 7.4 1 325 4 shouts
ÿÿ
ÿ Switch Ay, backup lamp Unit: N•m{kg•cm}
ÿGasket
SKIKI050
2-5-3 Points of removal

l. Disconnect the connector first from the service hole in the room
Then, (1) backup lamp switch Ay and (2) gasket
remove the port.
2-5-4 Inspection
1. Press the switch part of backup ramp switch Ay.
Check that there is continuity between the connector terminals when
Ru .
OFF
country
SK1KI 052
D-22
manual transmission
2-6 Transmission Floor Shift Ay Removal and Installation
ÿÿ
| T: 1 8.2 Sat 3.5 { 1 85 Sat 35} I
ÿ
ÿ
(1) Knob, shift lever

ÿ Boots Shift lever bar
ÿ
ÿ Clip
........ÿ Clip
ÿ Floor shift Ay, transmission
ÿ Retainer ÿ shift lever boot
SKIKI055
D-23
manual transmission
2-6-2 Points for removal
1. ÿRemove two clips with briar or the like.
Trouble•Work
the cable
so thatpart.
the pliers do not hit
SKIKIO56
2-6-3 Installation points 1. Insert

the shift cable and select cable into the shift lever body and
attach with the ÿ clip.
Around Ay •When attaching the clip , be careful not to hit
the cable with a hammer or the like.
•The clip is attached to the upper edge of the cable mounting surface and to the surface.
Insert until• After

attaching the eye end first, attach clips ÿ and ÿ.
SKI KI057
D-24
manual transmission
2-7 Remove and install shift cable Ay & select cable Ay
the law of nature
consideration
ÿC)
(1) Knob, shift lever

ÿ Boot shift lever
ÿ
ÿClip
...... ÿ Clip
ÿ Clip
......ÿ Clip
...ÿ Clip, band
... ÿ Cable Ay, Shift
... ÿCable Ay, select
SKIKIOH
D-25
manual transmission
1. Remove 2 each of ÿ and ÿ clips with briar or the like .
Garden • Make sure the pliers do not hit the cable.
to work.
SKIKI0511
2. ÿ Shift cable (plate washer on transmission side

) and ÿ Remove the select cable Ay.
Garden • Shift and select cables
end is 8Do not bend more than ° .
• After removing the clip on the bracket side first,
Remove the eye end side.
SKIKI060
2-7-3 Inspection
1. Inner of shift cable Ay and select cable Ay
Check that the cable slides smoothly.
2. Inspect the boot for tears, other damage or deformation.
be.
SKIKI061

l. ÿ and ÿ clips have brackets or floor
until the upper edge of the mounting surface of the shift Ay cable is flush with the
, ÿÿÿÿÿ
It is difficult .
Do not hit the cable body when inserting the clip.
to insert with
When .
• After attaching the eye end first, attach ÿ and ÿ
Install the lip.
Sktk9062
D-26
manual transmission
2. ÿAttach the band clip.•Route
so that thethe
select
parking
cablebrake
is below
cable.
D-27
manual transmission
2-8 Transmission floor shift Ay disassembly and assembly
Sanamix MP Grease
SKik,09
Amix MP Grease
//
Amix MP Grease
l T: 44 . 1 Shi 4.9 { 450 Shi 50} l Katoto Shi 2 .o { 65 Shi 20} |
ÿ ÿ Collar ÿ Joint ÿ Guide ÿ control rod

ÿRetainer ÿBolt ÿ shift lever boot control selector lever
washer -based ÿ
ÿBolt ÿLever ÿhexagon ÿÿ Seat transmission control select

ÿ ÿ
ÿ Shaft S/A, Washer -based hexagon ÿ Bush, control shaft lower

ÿ
Control ÿ control select control shift lever ÿ ÿStopper ÿ
ÿHousing , shift lever
Unit: N•mjkg•cm}
SKI K1065
D-28
manual transmission
2-8-3 Inspection
Inspect the following items and replace if defective.
deformation
1 shot
deformation, damage
Damage mark
broken Re
SKIKIOf&
2-8-4 Points of assembly

1 Place the ÿ control shift lever stopper on the ÿ control
Assemble to the trawl shaft S/A.
Country · The control shift lever stopper is
Assemble so that the grooved side of the stopper faces downward.
be.
SK1K1067
D-29
manual transmission
ÿ Transmission control select seat
Fill the inside of 2 with Amix MP grease , and
Assemble to the trawl shaft S/A.
Grease inside
filling
3. Attach ÿ Control Shaft S/A to ÿ Shift Lever How

(4 ) Washer-based hexagon
Tighten the two ports to the specified torque.
:D
unit · ÿControl shift lever stopper
ÿ Transmission control
Confirm that the convex part of the selection sheet is inserted.
to tighten the port.
SKIKIO 8
4. ÿ Assemble the 4 collars ( 3 types) in the positions shown in the right figure.
The outer diameter is 2 mm, 8.8 mm , 1 3.8 mm, 11.4 mm.
Outer diameter if, 1 3.8 Inner diameter ¢ 11.4 Outer diameter if, 12.7 Inner diameter if, 9.5
SKIKI O&II
D-30
Propeller shaft
3 Propeller Shaft
3-1 Propeller shaft removal and installation
3- 1 -1 supplies
mouth o IL 75W-85(GL-3)
SKI KI IO
pressure 46 .6 sat 7.4 {475 shi 7 beans]
_,.,/1
ÿ Shaft Ay, Propeller

Unit: N•m { kg cm f
SKIKI070

1. Propeller shaft flange joke and differential
After making alignment marks on the companion flange of the
Remove the 4 ports, and remove the ÿ propeller shaft Ay.
remove.
Trouble • Transmission Propeller Shaft Insertion

Use an oil stock to prevent oil from spilling on the
plug with par .
3-1-4 Inspection
1. Attach a dial gauge to the center of propeller shaft Ay .
to measure the .
run-out 0.5 nm or less
SKIKI072
D-31
Propeller shaft
2. Backlash in the axial and perpendicular directions of the universal joint
and check the rotating condition. .
3. Abrasion, damage, deformation, rattling on each part of the propeller shaft Ay
etc. .
SKI KI073

1. Insert the propeller shaft Ay into the out-butt shaft of the transmission. .
It's frustrating] •Forcibly inserting the propeller shaft will damage the transmission side oil seal and pusher.
2. After aligning the alignment .
marks that were made when removing the
ÿ Brooper shaft Ay and differential companion
Tighten the four mounting bolts of the on-flange to the specified torque.
Fasten.
SK"don

1. Check the transmission oil level and top up if low.
wetness It should be between 0 and 5 mm from the lower surface of the filler plug hole.
D-32
rear differential
4 Rear differential
4-1 Removal and installation of rear differential
4-1-1 Preparations
Ouri Three Pond 1212, Amix Hypoid Gya Oil 90 (GL-5)

SKI KI II

1. Lift up the vehicle .
2. Remove the rear wheel .
3. Remove the drain plug and gasket, and drain the differential oil . 4. Remove .
the rear axle shaft .
5. Remove propeller shaft Ay.
(Refer to D. 3-1 ( page D-31))
////
ÿ/
Main Detour 9 7. 3 Poo Wang Yuan "|
....ÿ Carrier Ay, Differential

Unit: N•m{kg cm}
SKtKtOBO
4-1 --4 Important points for installation

1. ÿ Differential key of rear axle housing Ay
Apply liquid gasket to the carrier Ay mounting part.
Wakuguchi Sou Three Pond 121 2
Skikiobi
D-33
rear differential
1. Install the rear axle shaft.
(Refer to D. Section 5--1 (page D-52) )
2. Install propeller shaft Ay.
(Refer to D. 3-1 (page D-31) )
3. After installing a new gasket and tightening the drain plug to the specified torque, remove the differential from the filler plug.
Inject the specified amount of essential oil.
I 0 to 5 mm from the lower surface of the filler plug hole. (about 0.8.0, )
Spring 61 . 6Sat 7.1N•m {600 100 kg cm} ( filler plug )
49. 1 mm 9. SN m {500 mm 100 kg cm} ( drain plug)
4. Install the rear wheel .
5. Lower the vehicle.
D-34
rear differential
4-2 Rear differential disassembly and assembly
I shape letter Model Product Name for road
09213-3102 1-000
Blur, crankshaft pulley I companion flange removal

Adjust
09219-87202-000
stand , engine overhaul I Differential disassembly and assembly
09548-87201-000
Otsuro Acquisition
Over Hall
, Differential Ditto
09308-10010-000
Removal of oil seal
blur, oil seal
s
09330-87301-000
drive pinion companion
TOOL, DRIVE PINION FLANGE
Whirl -stop when attaching/detaching the flange Same as above
Holding
09502-10012--000
S1 long Removal of puller, differential bearing 1
side
Differential side bearing
"_ 09515-1001
drive pinion bearing
Category 0-000 REPLACER , REAR
1 Press fit of inner race
AXLE BEARING
T.
09310-87301-000
water Oil seal and drive pinion

Rib Racer , Transmission 1 Bearing Rear Inner Press Fit
Bearing
`
09608-87501-000
'""' • , tool set ,
000 0oe Removal and installation of axle hub & I outer race
09630-24013-000
favorite ,
Tool set Oy J -reseal
Steering Rack I DrivePress fit Bearing
Pinion of inner race
09257-87201-000
rib racer , crankshaft bearing
1 Press fit of inner race
SK9KI92
D-35
rear differential
ÿ shape
Differential side bearing
Replacer , transmission bearing
ssji09309-87201-000 _ _ assembly
Tools Punch, plastic hammer

Instruments Dial Gauges , Torque Wrenches, Thickness Gauges
Oil Amix Hypoid Gya Oil 90 (GL-5), Amix MP Grease, Three Pound 1212
SK,""
D-36
rear differential
4-2-2 Work before
disassembly 1. Remove the rear differential carrier Ay from the vehicle.
(See D. 4-1 (page D-33))
2. Set the differential carrier Ay on the disassembly stand.
to do.
snow 0921 9-87202 1st
09548 - 87201 1st
SKtKt082
(1)
1. Inspection Backlash of differential ring
gear 0.08~o.1 511111
2. Differential side gear and binion gear backup

Crush
moisture 0.05~0.20nm
3. Differential ring gear and drive binion

Poor
tooth contact •After washing, apply a thin coat of yellow powder ,
rotate the flange, and check the tooth contact
between the ring gear and the drive pinion. do .•
Rotate the flange forward and backward to check points at several points.
inspect.
(See D. 4-2-6 (page D-43))
4. Turn the flange and check that it rotates lightly.
D-37
rear differential
revenge
Leaf T: 36 .8 7.3 {375 Sat 75} |
ÿ ÿ
\/ ÿ/ ÿ
\stomach
*
ÿÿ
/ÿ
'/ ÿ
1
[T : 1 1 7 .7 Sat 19.6 {1200
ÿ (ÿÿiiiiii'|
/, /'
A.
figure
degree
\Y Be
ÿ
\'\
9\, shaking
0
wealth
\\
mouth
\ ÿ
\
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ÿCap, differential bearing ÿ Flange S/A ÿ , Drive Pinion Companion

ÿ Case Ay, differential Seal type T Oilÿ
ÿ Shim ÿBearing ÿShim ÿ tapered roller

ÿBearing ÿGear, ÿ Rad the ball
differential ring ÿ Spacer ÿ ÿ drive pinion pairing
ÿCase differential
ÿ Bearing ÿ Pinion tapered roller
ÿ
ÿ Shaft differential pinion

ÿ ÿ Shim Differential drive
ÿ
ÿ Pinion ÿ ÿ Differential rental

Gear, differential side ÿ Outer race ÿ Outer ÿ tapered roller bearing ÿ Front
ÿ Washer ÿ ÿ side gas thrust race ÿ Carrier ÿ tapered roller bearing ÿ Rear
Nut ÿ ÿ Lock differential ÿ
Washer, plate
Unit: N•m{kg•cm f
SKIK1086
D-38
rear differential
4-2-4 Key points of
disassembly (1) Removal of the differential bearing cap 1.
No noise •Be sure to wear gloves and goggles while
working. When. Use a punch and hammer to make
alignment marks on the differential bearing
cap and carrier. 2. ÿ Remove the bearing cap. Since
the co-bearing cap and carrier are processed as one
piece, case
the combination
Ay and (3) shim
does (differential
not change.case
3. (2)Ay)
Differential
(for the case thrust ).
SKI K9088
Confused] •For reference during assembly, separate the shims into the back side of
the ring gear and the side of the tooth surface, and store them separately.
SKIKIOBII
4. Using SST, remove the ÿ radial ball bearing from the

differential case . Mesai 09502- 1 001 2-000
(2) Removal of differential ring gear 1.Make alignment

marks on the ring gear and differential case, remove eight
bolts , and remove ÿ differential ring gear.
ring Remove
gear. the
(Reference)
• If the ring gear is difficult to remove, use a brass
Tap lightly with a tick hammer to remove.
ci "' ) mark
SKIKl091
D-39
rear differential
(3) Disassembly of differential case
Noisy Neck •Be sure to wear gloves and goggles while working.
thing.
From ÿDifferential case to ÿDifferential pin

1 Neon, ÿ Differential side gear, ÿ Differential
Remove the axial thrust washer.
around the time Differential side gear and thruster
Store the washers as a set .
SKI Kl092
2. •Be sure to wear gloves and goggles while working.

Unlock the lock nut using a ratchet and hammer .
vinegar.
SKIKI013
3. Fix the companion flange using SST and

Remove the lock nut and ÿ plate washer .
[§ill 09330-87301-000
4. Using SST, remove ÿ companion flange S/A.

remove.
rnrJ 0921 3-31 021-000

5. Using SST, remove ÿ Type T oil seal .
vinegar.
eye 09308-1 001 0-000
6. Using a blast hammer, etc., remove ÿ differential

Tap the internal drive pinion to remove it.
need •Drop the differential drive pinion
Be careful not to two
D-40
rear differential
7. Using a bearing bouling attachment and a brace
and remove ÿ tapered roller bearing.
(Reference J Recommended tool No.145
No 1 45
SKI Kl097
8. Using SST and brace, ÿ & ÿ tapered draw

Roller Bearing Outer Race Front & Rear
remove it.
four 09608-87501-000 No. 3, No. 4
4-2-5 Inspection
Inspect the following items for wear, damage, etc., and
replace if necessary.
1 . Drive pinion & ring gear
(1) Tooth surface ÿ
(2) Drive pinion sub-brine part ÿ

(3) Bearing fitting ÿ
®
SKI KIO III
2. Said Gya & Binion

(1) Tooth surface ÿ
(2) Side gear boss ÿ

(3) Side gathering ÿ
To ÿÿÿ
(4) Pinion shaft fitting hole ÿ

(5) Differential case contact part ÿ
(6) Pinion shaft fitting part ÿ
(ÿ
ÿ ÿ
SK1Kl 1 00
3. Differential case
(1) Side gear boss contact part ÿ
(2) Pinion contact ÿ
(3) Ring gear mounting part ÿ
(4) Side bearing press fitting ÿ
(5) Body ÿ
ÿ
ÿ
SKIKI IOI
D-41
rear differential
4. Bearing
(1) Front bearing ÿ
(2) Rear bearing ÿ
( 3) Side bearing ÿ
Rotate it lightly and it should be smooth without catching or abnormal noise.
be .
ÿ SKIKII02
.5 COMBANION FLANGE
(1) Oil seal contact part ÿ
ÿ
(2) Subline ÿ
SKIKII03
6. Differential carrier
(1) Side bearing fitting ÿ
(2) Front and rear bearings
Outer race mating part ÿ
(3) Oil seal insert ÿ
(4) Axle housing joint ÿ
( 5) Body ÿ
SKIKI 104
D-42
rear differential
4-2-6 Assembly
(1) Assembly procedure
1. Temporary assembly of the differential drive pinion
2. Assembling the differential case
3. Differential side gear backlash adjustment …… … Standard value o. 10~0. 20-
Four. Assembling the differential ring gear
5. IJ ring gap adjustment ………… Reference value 0.08~0.1 5na
6. Adjusting the axial play of the differential case ………… Reference value 0~0.05DID
7. Tooth contact inspection of differential ring gear and drive binion
8. Same as above Tooth contact adjustment (drive binion protrusion adjustment)
9. Differential drive pinion assembly
Standard value 0.59~0.98N m

10. Bearing blade adjustment for single drive pinion
{6.0~10.0kg cm}
SKIKll4
(2) Temporary differential drive pinion

assembly
1. Using SST and brace, ÿ Differential carry
A, the same ÿ shims as when disassembled, ÿ & ÿ tapered
Roller bearing outer race rear & front
Assemble
snow 09608-87501 - 000 No.
7, No. 8•If the bearing is faulty, check the front
and rear as a set .
•Check the shims for any defects such as wear and scratches.
If so, install new shims of the same thickness.
be.
2. ÿ Differential drive using SST and brace
ÿ Tapered roller bearing (rear
inner ) 0 .
951 5-1 001 0- 000
snow 0931 0-87301 -000
Garden • If the bearing is faulty, check the front
and rear as a set .
• When replacing the drive pinion, remove the ring gear and
Replace as a set.
SKIKII06
D-43
rear differential
3. Tapered roller bearing (front inner )
, apply hypoid gear oil to the differential
Differential with the drive binion S/A
Temporary assembly to .
ÿ Dry pinion bearing spacer
the carrier
and ÿ shims are not assembled.
SKIKII07
4. Using SST and press, ÿ tapered roller bearing
rnf ] 09630 - 2401 3 -000 Set of . I l I II I
09630-2401 3-000 09257-87201-000
Use 09631 - 24020-000 I set

09631-24030-00D
09257-87201-000
Trouble • Bearing press fit is 19. 6KN {2000kg} or less.
.
What to do with load
SKIK1 1 08
5. [(13) Companion flange S/A, (12) Plate washer
ÿ and lock nut ÿ, and use SST to tighten ÿ
Tighten the locknut to the preload shown below.
be.
snow 09330 - 87301 -000
Garden • Apply oil to the threads of the nut and drive pinion.
•After .
assembly, in order to spread the bearings,
Rotate forward and .
reverse several times. •Do not install a type T oil seal .
ÿ Pre- load
0.59~ 0.98N•m {6.0~1 Okg cm}
D-44
rear differential
(3) Assembling the differential case
1. Attach ÿ side gasket to ÿ differential case .
Twasher , ÿ side gear, ÿ pinion and ÿ vinyl
Assemble the on-shaft.
around the timeApply Hypoid Galoil to each part .
SKIK III I
2. Measure the backlash of the differential side gear.

If it is out of the standard value, use the thrust washer shown in the table below.
select and adjust the

Around 0 .1 0~0.20nm
Differential side gas thrust washer selection table
Product number 1 Thickness (DD)
41361-87501 0.8
41361-87506 0.9
41361-87507 1. o
,,
SKIKII5
(4) Assembling the differential ring gear

1. Align the matching marks made at the time of disassembly, and
Assemble ÿ differential ring gear to the case .
and tighten to the specified torque.
Trouble • When replacing the ring gear, remove the drive pinion and
Replace as a set.
SKIK1 1 13
2. Using SST and brace, ÿradial ball bearing

assembly.
horse 09309-87201-000
SKI Klll 4
D-45
rear differential
(5) Inspection of ring gear backlash and
adjustment
1. (2) Replace differential case Ay with (13 ) differential

Assemble to carrier.
2. Place the ÿ shim that was assembled at the time of disassembly on the rear side of the ring gear.
insert.
Garden • Apply Hypoid Galoil to each part .
3. Align the matching marks made at the time of disassembly, and

Assemble the shaft bearing cap and tighten the four bolts.
Tighten to the specified torque.
Country ·Shim with differential case Ay inserted
Remove the bearing cap while pressing it to the side.
Assemble.
SKtKt t 16
4. Check the backlash of the differential ring gear.

inspect.
wetness 0.08~0.15nm
Trouble • If the backlash is large, add shims and
If it is too small, reduce the number of shims and .
adjust (the shims on the rear side of the ring gear).
Differential case side shim selection table

Product number Thickness (m)
90045-64049 0.15
90045-64050 0.20
90045-64051 0.25
90045-64052 0.50
SKI Kll6
(6) Adjusting the axial play of the differential case

1. Remove the bearing cap.
2. The clearance between the bearing on the tooth surface side of the ring gear and the carrier is
0 .
~0.05nm
Differential case side shim selection table
Product number Thickness (mm)
90045-64049 0.15
90045-64050 0.20
90045-64051 0.25
90045-64052 0.50
SKI K116
(Reference) • If it is difficult to assemble the shim, remove the ring gear.

After inserting the shim on the tooth surface side, insert the shim on the back side.
Tap lightly with a hammer to insert the shim on the rear side.
do.
D-46
rear differential
Align the matching marks made at the time of disassembly , and
.
3 Assemble the shaft bearing cap and tighten the four bolts.
Tighten with specified torque
SKIKI IU
D-47
rear differential
(7) Tooth contact inspection
1. Spread yellow powder evenly on both sides of the ring gear tooth surface.
Apply a thin layer to the tooth and check the pinion and tooth contact.
Garden • Drive Pinion Companion Flange

Rotate forward/reverse to see the contact of the ring gear.
Check the condition at several points.
per toe per flank per heel per face
drive pinio
CCn\ <= ring gya
CC
one drive pinion
ÿ ring gear
Keep drive pinion away from ring gear Bring the drive pinion closer to the ring gear
Choose a sim like . Choose a sim like .
Correct tooth contact
Readjustment
Install the protrusion amount adjustment shim (D-49).
Select again to , (2) Subsequent work

perform
However,
, per face hula ,
The ink hit is the backlash
In some cases, it can be adjusted within the range.
Carry out the work described in the next section.
(Assemble the oil seal )
SKIKl l7
D-48
rear differential
2. As a result of the tooth contact check, if adjustment is required, select shims (20) for adjusting drive binion protrusion from the table below, and
Adjust according to the disassembly/temporary .

assembly procedure described above.
Dry pinion protrusion adjustment shim selection table
part number Thickness (DID)
90045-64489 0,075
90045-64049 0.15
90045-64050 0.20
90045-64051 0.25
90045-64052 0.50
SKIKIIB
(8) Differential drive pinion assembly (bearing of single drive pinion)

ring preload adjustment)
1. Remove the differential case Ay and the differential drive pinion.
(1) Remove the four bolts, and remove ÿ the differential bearing cap, then remove the differential
Remove case Ay .
(2) ÿ Remove the shim.
Trouble • Separate the shims into the back side of the ring gear and the side of the tooth surface and store them separately for assembly.
(3) Using SST, remove ÿ lock nut and ÿ plate nut.
remove the shaft.
dan 09330-87301-000
SKIKll21
(9) Using SST, ÿ companion flange

Remove the disk S/A.
snow 0921 3-31 021-000
(1) Using a plastic hammer, etc. , remove ÿ differential

Tap the internal drive binion to remove it.
Trouble • Drop the differential drive pinion
Be careful not to
two
D-49
rear differential
1. ÿDifferential drive pinion, ÿDrive pinion bearing spacer and disassembled
Install the same ÿ shims.
Garden • Inspect the shim, and if there are any defects such as wear or scratches, install a new shim of the .
same thickness. •When replacing the drive pinion, replace it with the ring gear as a set.
2. Apply hypoid gal oil to the tapered roller bearing (front inner) and
Temporarily assemble to the differential carrier together with the longitudinal drive binion S/A.
3. Using SST and press, ÿ tapered roller bearing
Press in the ring (front inner ) . D l 6 3 Five: Store - ODO
I II I 09257-87201-000
[§fil]. 09630-2401 3-000 sets of
Use 09631-24030-000 09 6 31-24030-DDD
09257 - 87201 -000

Garden • Bearing press fit should be 19.6KN {2000kg} or less.
Do it with a load.
SKIKll24
4. ÿ Companion flange S/A, ÿ Plate washer ,

ÿ Assemble the lock nut and use SST to lock ÿ
Tighten the nut to the specified torque.
snow 09330- 87301 -000
Shift 1 1 7. 65 1 9. 55 N • m {1 250 Sat 1 50 kg • cm}
garden Apply oil to the threads of the nut and drive pinion.
apply.
• After assembly, in order to allow the bearings to conform,
Rotate forward and reverse several times.
• Do not install a type T oil seal .

5. Measure the bearing preload on the drive binion. ,
If it is out of the standard value, select the shim for brake load adjustment in the table below.
Adjust .
Wet mouthpiece Pre load
0.59~O.98N m {6.0~10.0kg cm}
Shim selection table for preload adjustment
Product number Thickness (1111)
90045-64004 o.25
90045-64005 0.30
90045-64006 0.40
90045-64007 0.50
SKlkl"
6. Using SST, remove ÿ lock nut and ÿ plate washer

Remove the companion flange S/A ÿ and install the new
Assemble the supplied ÿ type T oil seal .
Country 09310- 87301 -000
Garden • Amix MPg is applied to the oil seal lip.
Apply wreath all around.
• The oil seal is hammered in to the end face of the housing.
nothing.
SKl k1121
D-50
rear differential
7. Use SST to connect ÿ companion flange S/A, ÿ
Assemble the rate washer and lock drying tool
nut ÿ and tighten them to the specified torque.

Securely crimp the drive pinion to the bottom of the groove.
Tadashi . 9330-87301-000
good Impossible Impossible
SKIKI 128
D-51
axle
5 Axle
5-1 Removal and installation of rear axle
letter part number , Product name for road
ÿ shape
09511-87202-000
i Whirl-stop of hub
the law of nature
Stopper, brake drum
09912-87501-000 Remove axle shaft
s / “ Hammer, Blur Slide
Remove oil seal

/ 09308-00010-000
blur, oil seal
s
According to the rebracer , the transmission Oil seal installation
Kage09309-87201-000
Bearing _
Rebreather , Crankshaft Bearing installation

Bearing
T here 09257-87201-000 Mi
Ribracer , rear axle shaft Bearing installation
09515-21010-000 Bearing
Amix MP Grease , Three Pound 1212

Fats and oils
Amix Hypoid Gya Oil 90 (GL-5)
SKI Kl20
D-52
axle
3. Remove the drain plug and gasket. , Drain the differential oil .
®
ÿ [ T: 41 .7 Sat 7.3 {425 Sat 75} I
Amix MP Grease
ÿ'""ÿ>
finished
T: 21 5.8 39.2 {2,200 Sat 400 ÿ

(1) Pin, cotter
......ÿ Drum S/A brake ,
... ÿPlate S/A, brake backing
ÿ Spacer, rear axle shaft
......ÿ Shaft SIA, rear axle
......ÿBearing radial ball
ÿ
...... ÿSeal , Type T Oil

Unit: N m { kg cm }
SKIKl l40

ÿ
1. After removing ÿ the cotter bin, use SST to remove the ÿ block.
ÿ
Prevent the rake drum S/A from turning, and tighten the lock nut and D
and spring washer , Remove the plate washer
vinegar.
Snow 0 951 1-87202-000
SK1Kl l41
D-53
axle
2. Using SST, remove ÿ rear axle shaft SIA .
remove.
snow 0991 2-87501-000
3. Using a press, press the ÿ radial ball bearing onto the ÿ

Remove from rear axle shaft S /A .
SKI Kll48
4. Using SST, remove the ÿ type T oil seal .

vinegar.
Darkness 09308-0001 0-000
SKIK1 144
5-1-5 Inspection
1 . Check the rear axle shaft for twists, cracks, etc.
inspect.

1. Apply an oil seal to the entire circumference of the rib surface of the new ÿ type T oil seal .
After applying mixed MP grease , use SST to

Install in rear axle housing Ay .
rnYJ 09309-87201-000
D-54
Axle
2. Using SST and press, remove ÿ radial ball bearing
ring to ÿ rear axle shaft S/A.
snow 09251 -87201 one spider
0951 5-21 01 0- spider
oo SKIKl147
3. ÿBrake backing of rear axle housing A Shahui I

Apply liquid gasket to the mounting surface of the ring plate S/A Liquid gasket application
do.
Sonoguchi Sonoguchi Three Pond 1 21 2
SKIK1 148
4. (5) Amites are attached to the subline of the rear axle shaft S/A .
Apply KSMP grease .
5. Use SST to ( 2) stop the rotation of the brake drum S/A.

and remove the plate washer and spring washer.
After installation, tighten the castle nut to the specified torque.
Declaration 0951 1-87202-000
workman · Tighten the castle nut to 2,000± 200 kg •cm. SST
After tightening, install the cotter pin on the retightening side.
Align the holes.
SKIK1 150

1. Install a new gasket , tighten the drain plug to the specified torque, and then remove the differential from the filler plug.
Inject the specified amount of essential oil.
Wet distribution From bottom of filler plug hole
be between 0 and 5 nm
Yuguchihai Amix Hypoid Gya Oil 90 (GL-5)
Total capacity 0.80
2. Install the rear wheel .

3. Lower the vehicle.
D-55
Axle
5-2 Remove and install rear axle housing Ay
5-2-1 Preparations
Times Amix MP Grease

SK1 K1 09

1. Raise the vehicle .
3. Remove the drain plug and gasket, and drain the differential oil. 4. Remove the .
rear axle shaft .
5. Remove the rear differential.
6. Remove the rear shock absorber .
(Refer to E. 2-4 (page E-15))
l T: 49.0 sat 4.9 {500 sat

consideration
'Skin - l T: 41 .7 Sat 7.3 { 425 75} ]
ÿ
ÿBolt ÿ U
ÿBumper ÿ rear spring
ÿHousing Ay, rear axle
SKI K1155
D-56
Axle
5-2-4 Points for removal 1.
Disconnect the axle and the brake pipe on the
vehicle side. 2. With a garage jack, remove ÿ rear axle housing Ay
E-one"
support. Trouble •Keep supporting the garage jack.
SK1K1 1511
3. Remove the 4 nuts on each side, ÿ U bolts (2 on each

side), ÿ Remove the rear spring bumper . 4. Operate
the garage jack to ÿ rear axle how
Remove the ring Ay from the vehicle.
SKI Kll57
5-2-5 Installation points 1. Lift

the garage jack, join the ÿ rear axle housing Ay to the
ÿ--"
leaf spring, and
Install the U-bolt and tighten it to the specified
torque. 2. Connect the brake lines on the axle side and the vehicle side.
SKIK1 156
5-2-6 Work after

installation 1. Install the rear shock absorber .
(Refer to E. 2-4 (E-1 page
5)) 2. Install the rear differential.
(See D. 4-1 (page D-33)) 3.
Install the rear axle shaft.
(See D. 5-1 (page D-52)) 4.
After installing a new gasket and tightening the drain plug to the specified torque, remove the drain plug from the filler plug.
Inject the specified amount of facial oil. To
be between 0 and 5 nm from the lower
surface of the wet filler plug hole
Sonoguchi Sonoguchi Amix Hypoid Gya Oil OO (GL-5)
Total
capacity 0.8.Q. 5. Install rear
wheel . 6. Bleed air from the brake .
system (Refer to E. Section 4-1 (page E-35).)
7. Replenish brake fluid up to the M Shinzawa line in the reservoir .
D-57
engine mounting
1 Engine mounting
1 -1 Engine mounting removal and installation
4 Torque wrench
SKICIOI
Umbrella® fT: 4. 5 Sat 5.9 { 250 60t 1
ÿÿ
[Danzu King Sheeting 3.5 {19 Fuji 5 Shi 5 ÿ ÿ
/® | T:19.2 3.5 { 1 95 35[
® | T: 24.5 5.9 l250 Sat 60} |
handwriting
Sono
ÿCooker ÿ3
Unit: N•m{kg cm}
SK1CIOOI
1-1-3 Inspection
If there is a problem with each engine mounting, refer to the gaps between the stoppers while the vehicle is in the vehicle.
Replace part.
E-1
engine mounting
(1) Engine mounting stopper clearance
(light)
SKtCI002

(Left)
SKICI003

(rear)
SKICI004
E-2
Suspension
2 Suspension 2-1 Wheel

alignment 2-1 -1 Preparation
;;1 :::2::::;::Sheet];:Ya Breather gauge. Camber caster gauge. Dial gauge

SKIC102
Confused] • Measure the wheel alignment with the vehicle empty (fuel full, spare tire removed).
thing.
2-1-2 Inspection before wheel alignment measurement (1 ) Tire

size and wear inspection 1. Check that there is no difference in
size and that the difference in wear on the left and right side and uneven wear are not significant.
(2) Tire pressure check 1.9kg /

yellow
wheel) Wet 2.2kg /yellow (rear (front
wheel)
(3) Tire deflection

check 1. Use a dial gauge to check tire runout. ÿ 1.4
hits (vertical runout) 2.0nm (horizontal runout)
SKICI005
(4) Inspection of port tightening condition of related parts
(5) Check for looseness of

related parts1 . Ball joint
backlash 2. Steering linkage
backlash 3. Suspension related
backlash 4. Front wheel bearing backlash
2-1-3 Front Wheel Alignment Inspection and Adjustment (1 ) Toe -in Inspection 1. Shake
the vehicle and stabilize the vehicle. Push the vehicle straight ahead for 5 m. J. When
the vehicle is backed, up, always move forward by the distance that was backed up.
2.
E-3
Suspension
3. Adjust the height of the pointer of the toe-in gauge to the center of the front wheel axis.
Match the height and put it in the rear side of the tire.
4. Mark the tread center on the back of each front tire.
.
, Measure the distance between marks (A dimension)
death
rotate
5. Slowly push the vehicle forward and bring the front wheels to 180
Ru.
Trouble • 1 Do not rotate more than 80° . A.

If it rotates, 3. Start over. 1--
SKtCIOO&
6. Measure the distance between the marks (B dimension) at the front of the vehicle.
Front
7. Find the toe -in (A dimension - B dimension).
wet 1 0 2. Ornn B.
A.
SKI CI 007
(2) Toe-in adjustment

l. Loosen the tie rod end locknut. Lock nut
2. Pry the left and right rack ends in equal amounts in opposite directions.
.
Turn to adjust so that the toe -in is within the standard value.
3. Tighten the tie rod end locknut.
Around 36.8 7.4 N m {375 Sat 75 kg cm}
Trouble •The amount of movement of the left and right tie rods should be the same .
• The length shown in the right figure must be the same ( wheel
(Because there is a difference in the angle of inclination).
• Do not twist the poot when adjusting . SK1 CI008
Time to check the toe .

Four .
-in again 1 0 Sat 2.

, caster
011111 (3) Camber inspection , Kingpin angle
1. Disc wheel and camber casterkin

2 places vertically from the ground on the pin gauge, water direction
Mark two places on each .
SKICI009
E-4
Suspension
2. Set the turning radius gauge .

(1) Set the turning radius gauge to 0. Align withÿpoint and lock
do.
(2 ) At the center of the turning radius gauge Tire tread
When the vehicle is put on so that the .
center of the
When the vehicle is empty, pull the prop so that the front wheelsdo not turn.
Using a brake pedal pressure , etc.

Inspect with the foot brake .
applied•Portable type turning radius
If you use a gauge , also attach a gauge and SKICIOIO
Place a table of the same height and keep it horizontal.
•Make sure that the stop lamp switch does not light up.
To , Remove the stop lamp fuse and inspect
to do.
3. Install the camber caster kingpin gauge

Ru .
(1) Turning Radius Gauge Pointer ” 0 ”according to
Unlock the turning radius gauge .
(2 ) Marks on disc wheel and camber cast
Install so that the markings on the tracking pin gauge are aligned
Ru .
SKICI012
4. Check camber .
(1) Check straight ahead.
(2) Place the gauge on the water line so that the air bubble in the gauge is centered.
set. Dai 1 medium
(3) Check the center position of the air bubble on the gauge for measuring camber . I l l
sounding snow
read.
ÿ
wetness 0 1 0' Sat 45'

Utsutsu ( Kikantou) ÿ[ m(O
SK1C1013
E-5
Suspension
5. Check the caster angle and kingpin angle (right wheel).
•
I II `I
I I I I
ÿ Kink pin
left car i
kink bin right wheel
right wheel
- Harvest I Huke (: vs.): Tokui,: tn:; Sonomasa:
eÿi: leaf; ': I:t; holly fee: r,t': yes
Left wheel string
smClou
(1 ) Turn the steering wheel to the right until the turning radius gauge reads 20° . (2) Turn the adjusting
"
screws for the caster angle and kingpin angle of the gauge to remove each air bubble to ” 0 ”.
match the
(3 ) Turn the steering wheel to the left until the turning radius gauge reads 20 degrees . (4) Read the
gauges for measuring the caster angle and kingpin angle on the center of the air bubble.
Wet 7 1 2 6. Check ÿ
5' 1 ° (king
0 (caster
pin angle)
angle) 1
° 39' Sat 1
caster angle and kingpin angle (left wheel).
(Reference J Camber, caster , and kingpin angles are adjusted to standard values in advance, and are non-adjustable
vinegar. 7. Remove the gauge.
(4) Wheel angle inspection 1. Turn

meeting
the steering wheel all the way to the left and right, and ®Inner
ringÿ _
Check the turning angle of the Front
le. Wet opening Inside 39° 50' Sat 2
0 ®
Outside 32° 2.
30' 2
Adjust 0
.
if there is a difference in cutting angle between left and right.
SKICIOU
E-6
Suspension
(5) Wheel steering angle adjustment

1. Loosen the tie rod end lock nut . Lock nut
2. Make the length of the screw part of the left and right rack ends the same amount.
unit · Do not twist the poot when adjusting .
3. Tighten the lock nut on the tie rod end.
Spring 36. 8 7 . 4N•m {375 75kg • cm}
SKICIOOB
(6) Front side slip inspection

(Reference J • Check and adjust even if the side slip value , If there is a problem with the hot water, mark the above items.
is within the standard value.

1. Check the side slips with a side slip tester .
wetness In 5 nm to Out 5 nm
E-7
Suspension
2-2 front Remove and install the shock - up knob

shape letter Product number Product name for road
after s
s
ÿ
0961 1-87701-000
Blur, tie rod end
Disconnect steering tie rod end
09727-30020-000
T. Compressor, front coil coil spring compression

Spring ring
:: Yu: "Reni P Grease "

SKICI03

2. Remove the front wheel.
3. Remove the front side panel.
(Refer to Section F.4 (page F-10))
4. Drain the brake fluid .
Compacted 9 {400Sat50}]
soil 4 .... ÿBrake Ay, front
... ÿ End S/A, steering tie rod
....(3) Arm S/A, suspension lower
... ÿÿ Bracket ÿ Nut ÿ stabilizer Lolo: Three l 0---—One ÿ
ÿ Cover bearing dust
ÿ
ÿ Support Ay, front suspension

ÿ Bush, front shock absorber ÿ To 11—ÿ
ÿ Seat ÿ front spring upper
ÿ
Cover Shock Ab'Nover Dust

ÿ ÿ
White ÿ
.... ÿ Spring ÿ Bumper front coil ÿ
ÿ ÿ Ab'no bar ÿ front spring

Ay, front shock
Unit: N•m] kg cm}
adventure: finished
ÿÿ
- sac
&
SKIC1020
E-8
Suspension
2-2-4 Points for removal

1. Disconnect the brake tube and remove ÿ front brake Ay.•Take care not to
damage the brake tube when removing it.
2. Using SST, separate the ÿ tie rod end from the steering
knuckle. Garden • SST
When using SST , be sure to hang a sling from an

appropriate part on the body side to prevent it from
falling.•The removed lock nut cannot be reused.
snow 0961 1-87701-000
3. Using SST, remove ÿ lower from the steering knuckle.

detach the farm. • SST
When using
SSTthe, be sure to hang a sling from an appropriate
part on the body side to prevent it from falling.•The
removed lock nut cannot be reused.
wealth 0961 1-87701-000
4. ÿ Separate the strut bar bracket from the vehicle, remove the
upper part of the absorber Ay, shock w/coil spring from the
vehicle, and then remove the lower part. Also remove the
side. Trouble
coil•App'Nover
spring fromAy.
theWhen removing
vehicle the shock
, be careful not to w/ SKICI025
damage the body.
Five. Attach the SST to the ÿ coil.

Install with the
between
widestco-hooks.
distance
•Do not use an impact wrench to compress the

spring. Tomi 09727 -30020-000
open space
SK1CI021
E-9
Suspension
2-2-5
Inspection Inspect the following parts, and replace if defective.
1 damage deformation
deformation of the comb part [mouth:
Union - Transformation, Rupture
Settling--''
SKI CI022

1. Using SST, install ÿ coil spring to ÿ shock
absorber Ay. need
• SST is designed to maximize the distance between hooks.
be installed.
•Do not use an impact wrench to compress
the spring.•Align the grooves of the spring
seats on the upper and lower sides with the
ends of the springs.
snow 09727-30020-000
2. Attach the absorber Ay, shock w/coil spring bottom
Temporarily attach the side , and then top to the vehicle.
to the ÿ lower arm .•Be
careful notbody
to damage the
when installing the absorber Ay , shock
w/coil spring to the vehicle . 3. Secure the
stabilizer bar with the ÿ stabilizer bracket.
Install on vehicle.
Confused] •Since the stabilizer bracket has directionality,
install it by referring to the diagram on the right.
SK1C1035
E-10
Suspension
4. Alignment of steering knuckle and ÿ backing plate

Apply liquid gasket to the facing surface (whole circumference).
Trouble • Brake mounting bolt holes (4 places) Sealant

Do not let it adhere.
Outlet arrangement Die
Happondo Nn 4 5 . (1) Install the brake drum .
< Brake drum installation procedure>
(1) Tighten the nut to the specified torque.
Naogawara 42. 2 Shi 4. ON • m {430 40 kg • cm}
(2) After turning the nut back about 45° , rotate the brake drum 2-3 times. SKIC1124
Rotate it back and forth to check the smoothness of the bearing.

(3) Fit the box of the box wrench to the nut, and
Dig out and tighten the nut.
(Reference) • Do not tighten the nut directly with your fingers.
Please do not do this as it will be insufficient.
(4) Castle nut , Install the cotter bin, and
Fill the inside of the hub with grease and install it.
Wakuchoku Amix MP Grease (14 g)
1. Inject brake fluid and bleed the air.
2. Install the front side panels.
(Refer to F.4 (page F-10))
3. Install the front wheel .
Spring 1 03. 0 1 4. 7N m {1 050 Sat 1 50kg cm}
4. Jack down the vehicle 5. .
Perform wheel alignment .
(Refer to Section E 2-1 (page E-3))
E-11
”
Suspension
2-3 Suspension Lower arm & stabilizer Bar removal and installation
l\ shape letter Model Product Name for road
09611-87701-000
Lower arm pole
Blur, tie rod end
/ 09301-87701-000 Tool, clutch guide

Remove the lower arm bush,
attachment
s
Lower arm bush removal and
09506-87301-000 Tomoe Ribracer , Differential Drive Pinion Bearing
Cone , Rear
installation
T. 09618-87301-000
ÿ ÿ Ri Rebracer , transmission pole joint Dust cover press fit

Bearing
Instrument G } Sand clench

SK9C904
4 {37 ÿÿ}
Hill: 36.8 Shi 7.
:, ÿSad `fD] '
ÿNut
Retainer
ÿÿ ÿ Cushion ...
ÿ Bracket ... ÿ
ÿ
stabilizer
ÿ
Bar ÿ Bush, stabilizer

ÿ
stabilizer
ÿ Cushion ÿ ÿ strut bar
Clip
*' : Amix MP Grease

Drink”. 4 soldiers 9
ÿNut Castle ÿ
..... ÿ Arm S/A, suspension lower

9 {850 King mm] ........ ÿ Bush , lower arm
] Item 3 . ... ÿ Cover Lower Ball Joint Dust
Unit: N•m{kg•cm} ÿ
SKICI030
E-12
Suspension

1. Using SST, remove the ÿ suspension from the steering knuckle. SST
Disconnect the lower arm SIA.
Garden • When using the SST, be careful not to drop it.
Attach a sling to an appropriate part on the body side.•
Removed locknuts cannot be reused.
g0961 1-87701-000
SKIC1025
2. Noisy snow •Be careful not to touch your hands during press work, as it is in an unstable state.
Be very careful while supporting with

Using SST and press, ÿ suspension lower
09301-87701-000
Remove the ÿ bush and lower arm from the farm S/ A .
snow 09301-87701-000
09506-87301-000
SKICI031
2-3-4 Inspection
.
Inspect the following parts, and replace them if they are found to be defective.
ÿ
damage
melon , v side, heart, heart 9 ÿ

Mamoru
deformation, damage
De:
Australia
Talent Wound
§ 10
deformation, loss
Sorrows§ _
SKICI032
E-13
Suspension

1 During the press work, it is in an unstable state.
Be very careful while supporting it with the support.
Use SST and press to lower the lower arm

ÿ Lower ball joint duster
Press fit the .
barrnTI 09618-87301-000
Socket part and knuckle attachment during assembly
Do not allow grease to adhere to the part .
SKICI033
2. Noisy week •During press work, it is in an unstable state.

Be very careful while supporting with the sling.
Country where ÿ bushing lower arm is press-fitted to , 09301-87701-000
the lower arm using SST .and brace
09301 - 87701 -000
09506 -87301 -000
SKICI031
3. Attach ÿstabilizer bar to ÿstabilizer bracket

Attach to the vehicle with
Garden • The stabilizer bracket is directional.
Therefore, refer to the figure on the right to install.
•Does the cushion retainer have a direction ?

Front of vehicle . .
Install by referring to the diagram on the right.
stabilizer bracket
SKICI035
Cushion ÿ
stabilizer bar
retainer
SKtC1036

ÿ Twilight Country 1 03.0 Personnel 1 4.7 N m {1 050 Sat 1 50 kg • cm}
3. Check wheel alignment.
E-14
Suspension
2-4 Removing and installing the rear shock-up knob

2-4-1 Preparations SKI CI05
ÿ Torque wrench
2-4-2 Work before

removal 1. Jack up the
vehicle. 2. Remove the rear wheel .
2--4-3 Removal and installation procedures
]
9 ÿÿ
ÿNut
IT
ÿ ÿÿ ÿ ÿÿÿÿ
,\ {ÿ
\
hmm
ÿ ÿ
58 hmm Unit: N•m {kg•cm}
B 44: B _,
of nature [' the law
dko *: Non -reusable parts
SKI CI041
2-4-4 Inspection
lead
( 1) Checking the operation of the shock absorber
1. Extend and retract the shock absorber. Wetness: It
should expand
response
and contract
and make
withno
a constant
noise.
-t
SK1C1042
2-4-5 Work after

installation
• 1 Install the
rear wheel. Straight 1 03.0 14.7 N m {1
050 1 50 kg • cm} 2. Jack down the vehicle.
E-15
Suspension
2-5 Removing and installing the rear leaf spring

ÿ Torque wrench
SK1 CI05

. Jack up the vehicle with a 2-post lift and
Support 1 with a garage jack .
Garden and 2-post lifts are attached to the leaf spring mounts.
and make sure it does not hang over the spring.
When.
to the spring
no money
to do
SKICI045

3. Remove the side skirts .
Four . Remove the battery. (When removing the left side)
E-16
Suspension
I T: 39.2 9.8 \400 Sat 1 0
®ÿ _
'Beat'®
Unit: N•m]kg•cmf
SKICI043
2-5--4 Main points of removal

1. Slightly lower the garage jack to separate the spring from the axle, ÿ Rear spring shackle
Remove the S/A and separate the rear leaf spring from the vehicle.
Around Removed nuts cannot be reused.
E-17
Suspension
2-5-5 Inspection
Inspect the following parts, and replace if any are found to be defective.
Deformation, damage 1 easy : Deformation,
fatigue / Deformation, damage
deformation, damage
SKICI044

Lift the garage jack , connect the axle to the leaf spring, attach the ÿ rear spring bumper to the spring,
and ÿ U Tighten the bolt with the nut. Stiffness] Tighten the nut so as not to bend the port.
Straight 49.0± 4.9N•m {495±45kg • cm}

1. Install the battery .
Install
. Install
thethe
rearside
wheel
skirts
. .2
3. Approximately 1 03.0 1
4.7 N • mcm}
{1 050
4. Jack
1 50 kg
down
• the vehicle.
E-18
Steering
3 Steering
3-1 Steering wheel (2-spoke, made of coconut oil) Removal and installation
3-1-1 Preparations
words - Grease SKICI06

1. Remove the ÿ terminal of the battery .
2. Put the steering in the straight-ahead state.
|T: 34.3 Sat 4.9 {350 Shiba ÿ

ÿI
f
two or three}
B
ÿ
Unit: N•m {kg•cm f
....... ÿPad S/A, steering wheel
ÿNut lock
ÿ
ÿWheel S/A, steering

ÿPlate S/A, horn button contact SKtCt050

1 . ÿ Remove the steering wheel pad S /A .
Use needle-nose pliers or an O screwdriver to hold the wheel
Remove the hook of the bad S/A from the valve side and take it out.
Korokorei] • Remove the claws (four places on the top and bottom) so as not to damage them.
vinegar.
SKtCI052
E-19
steering wheel
3-1-5 Install the horn

1. terminal .•Firmly fit the contact
plate into the
wheel
groove
side.on the steering
SKICI053
2. Apply Amix Rubber Grease to the areas shown in the figure on the right.
be.
wreath application ÿ/// //--—

SKICIOM
3. ÿ Install the steering wheel pad S/A.•Forcibly install

it so as notthe
totop
damage
and bottom).
the claws (four places on
SKIC1055

1. Check if the steering is going
straight. 2. Attach the ÿ terminal of the battery .
E-20
Steering
3-2 Removal and installation of steering column Ay

SKICI07

1. Remove the ÿ terminal of the battery .
2. Remove the steering wheel Ay.
3-2-3 removal,
'
ÿ
ÿ
ÿ
ÿ
IT : 1 2 . 8 3.o {130 30} |

3
"
d
0
/
ÿ
each other
:ÿ
] B.
ÿ
Unit: N•m (kg•cm )
ÿ ÿCover ÿ Steering column lower

ÿCover main shaft joint
ÿ
........ÿBolt
ÿ Switch Ay, turn signal
.......ÿ Column Ay, steering .... ÿ Bracket Ay, Steering
ÿCover steering column upper
ÿ Column upper w/ switch
SK1C1060

1. Remove the ÿ bolt (column side) of the universal joint, and take out the ÿ steering column Ay.
Trouble • Fully loosen the port of the universal joint on the steering gear side as well. .
E-21
steering wheel
2. ÿRemove the steering lock Ay and install a new steering wheel.

Replace with the ring column Ay.
<How to remove the steering lock Ay >
(1) Using a drill, remove the steering lock set bolt .
Drill a hole large enough for an inverted tab to stand up.
(2) Use the reverse tab to release the steering lockset button.
Remove the roots, Remove the steering wheel
(2).
(3) Install new steering lockset bolts (2).
Tighten to the specified mounting torque . SKI C1061
3-2-5 Inspection
.
1. Inspect the following parts and replace if defective.
Wear of serrations
Tube damage 1 easy deformation Wear of serrations
SK9C9062

1. (3) Attach steering column Ay to universal joint
and tighten the ÿ bolt (column side) to the specified torque . the guri direction
wear. "/
{250 50 kg • cm}
24.5 4.9 •NPorto
m is always a universal joint ZAG
Install from the direction of the arrow.
Gear Ay side
SKtCI063
3-2-7 Work after removal

.
1. Check the straight-ahead state of the steering
2. Install the steering wheel Ay.
3. Attach the • terminal of the battery.
E-22
Steering
3-3 Disassembly and assembly of steering column Ay

Times Amix MP Grease SKICI08
1. Remove the • terminal of the battery.

2. Remove the steering wheel Ay.
3. Remove the steering column Ay.
ÿÿÿ
... ÿ Ring, E
....... ÿ Bush
ÿ Shaft S/A, steering main
I \l No. 1
I ÿ Ring • ÿ ÿ Steering column ÿ
Tube S/A, steering column
SKICI064
3-3-4 Key Points of Disassembly

1. Secure the steering column Ay to the vise.
Country · Attach a copper plate or aluminum plate to the vise base so that the column tube is not scratched.
make it
2. Remove the E-ring ÿ using the snub ring expander.
Trouble • Removed E-rings cannot be reused.
3. Remove the ÿ bushing from the steering column tube using a screwdriver or the like.
About • Removed pushes cannot be reused.
E-23
Steering
3-3-5 Inspection
1. Inspect the following parts, and replace if any are found to be defective. .
Serration part
the wear of
Bending of the main shaft
Wear of backlash of bearing
Abrasion and settling of bushes
SK1 C1065

1. ÿ Attach the steering main shaft to the steering column tube.
< Grease application area>
5 to 10 15~25
SKICI067
When installing the co-steering main shaft , apply Amix MP grease to the areas shown in the above figure.
to clothe
•Apply grease to ÿ before assembling the main shaft .
•Apply grease to ÿ after assembling the main shaft.
Around 1 g or more / 1 point (applied to the entire circumference of the shaft)
2. ÿInstall the steering column.ÿ Bush

protrusion
Chu Wave _
m •Because there is an assembly direction for the push,
Try not to.
•Make sure that the end face of the tube and the end face of the push are
match. Bush
SKICI 066
E-24
Steering
3-3-7 Work after assembly

1. Install the steering column Ay.
2. Install the steering wheel Ay.
(Refer to E. Section 3-1 (page E-19))
3. Attach the • terminal of the battery.
E-25
steering wheel
3-4 Removing and installing the manual steering gear Ay

3-4-1 Preparations
shape letter Model Product Name for
l\ road
Steering tie rod end disconnect
s ” 09611-87701-000
s
T.
Blur, tie rod end
instrument torque wrench
SK, C'°'

ÿ
, g[
ÿ
:: be ÿ
helmet
]
l
Shame 1_ `
direction_mouth
Unit: N•m1kg • cm}
® ,, : f,, /],,; / I1 ÿBolt

ÿ Shaft S/A, steering
1917 Intermediate
IIL
ÿ Cover, steering
Three 7.4 {475 Sat 75} |
peony universal joint
... ÿ Nut
ÿ Bracket ÿ Steering
Package - ÿ ÿ *
Rack housing No 1
ÿ Gear Ay, steering
SK IC1070

1. ÿ Disconnect the steering intermediate shaft S/A from ÿ steering gear Ay.
Garden • Fully loosen the port of the universal joint on the steering column side. .
E-26
Steering
2. Using SST, cut the ÿ nut on the tie rod end.

SST
Release.
Around When using the SST, be careful not to drop it.

Attach a sling to a suitable part on the side of the pod.•
Removed locknuts cannot be reused.
Kagaki 0961 1 - 87701 -000
SKICI024
3-4-5 Inspection
,
Check the following parts Replace if defective .
thunder _
Catching _ tear tear
Wear of serrations
breakage/damage
SKI CI071

Around 1 03. 0 1 4. 7 N m {1 050 Sat 1 50 kg cm}
3. CHECK WHEEL ALIGNMENT .
(Refer to Section E 2-1 (page E-3))
E-27
Steering
3-5 Disassembly and assembly of manual steering gear

\ shape letter Product number , product name for road
For fixing stunt , rack and pinion slack housing

)
Chang 0 961 2-0001 2-000
Tearing rack housing
Locking the steering rack guide

Wrench, steering rack end removal and installation JIJ
San 0 9617-87201-000
Removing the radial ball pairing

puller , universal )il
s 0 9950-20017-000
0 963 1-87201-000
s Shinzo l) I Remover . Removal of steering pinion Best steering pinion ij

A ring
0 9527-100 11-000
T.
three For remover , rear axle shaft bearing (pinion) press fit
A ring
Replacer . For installing counter shaft flow oil seal

Kan 0 9310-87301-000
point bearing and
Socket steering pinion for measuring preload (pinion)

0 961 6-87502-000 Aling Adjusting
Engineering
mark Simple spinner
Rack guide spring cap
For removal and installation
.
*How to make: Attach two nuts with a width across flats of 17 mm to the port.
tool
Confused with screws and double nuts
snap ring expander
Instrument Torque Wrench
Fats and oils Amix Long Life Grease

SK9C190
1. Using SST, fix the steering gear Ay in the vise

do.
ÿ 0961 2-0001 2-000
Ba
/
SKICl072
E-28
Steering
Alignment mark
speech ox
SKICI073
Roof tile ÿ (inner surface)

——ÿ*.. (Whole circumference of the lip)
®
7.4 G. m
{575 Domoto
Oÿ ÿ
ÿ
ÿÿ ]: 0}——ÿ
`
[ +-
0
` `ÿ`` ÿÿ[ [
e
ÿ
ÿ | T: 56.4 Sat 7.4 {575 Sat 75} | ÿ
ÿ ÿ5
Q.
field
ÿB _
:3
ÿRack Steering
....... ÿ End S/A, steering tie rod ÿ
ÿBand steering rack boot No2

ÿ
ÿCover dust ÿ
ÿ Band ÿ steering rack boot .... ÿSeal , type K oil

... ÿ Boot .......
ÿ steering rack ÿ Ring, snap
ÿ End S/A, Steering rack No.1 .... ÿ Ring .......
ÿ Shaft snap
... ÿ Nut .......ÿrack end ÿ Bearing radial board ÿ
ÿ Nut Hexagon ÿ
ÿ Pinion, ÿ Steering
....... ÿ Cap, rack Khalid spring Grommet ÿ ÿ steering rack housing
ÿ Spring ÿ ÿ Compression Housing S/A, Steering rack

Guide ÿ rack
*' : Amix Long Life Grease

SKICl074
E-29
Steering
3-5--4 Points of disassembly

Using a spanner (width across flats: 19Dl!l, width across flats: 27 countersunk), ÿ
1 Remove rack No. 1 end S/A (RH, LH).
SK ICI075
2. Use SST to remove ÿ hexagon nut.

[§ID 0961 7 -87201 -000 (width across flats 39111ll)
Confusion. Before removing the hexagon nut, remove the rack
Aligned with the guide spring cap
mark .
Alignment mark
SKI CI076
3. Using a simple spinner , pull the ÿ rack guide spring

Remove the cap.
(Reference J • Simple spinner (width across flats 17DID)
Four . ÿ Remove the steering rack.

Trouble • When removing the rack, use the rack tooth surface to pull the rack out.
There is a risk of scratching the shoe, so be sure to

Pull out to the ring side.
•Pull out the rack straight without rotating it.
vinegar.
• Clean the steering rack S/A with washing oil. SKICl077
Remove any grease remaining in the .

root of the tooth. 5. Steering pinion (with bearing) using SST
Remove the
Country 09631-87201-000
SKIC1 078
E-30
Steering
6. Using SST, remove ÿ radial pole bearing.
remove.
snow 09950- 2001 7-000

Earthquake] •The removed bearings cannot be reused.
3-5-5 Inspection
.
-
1 . Inspect the following parts, and replace if defective.
of
/
] “{ g
ÿ relief
" ÿ ÿ
:7
rank
ÿ{0 ÿ
9
,
@
05
[
damage, deterioration r/5

Push wear, damage [
SKICIOBO

1. Using SST and a press, install a new ÿ radial ball bearing.
Press the ring into the steering pinion.
snow 09527-10011-000
Q.
SKICIO II
E-31
Steering
2. Use a snubbing ring kiss pander to attach the new ÿ

ÿ
Install the shaft snub ring.
3. Steer previously assembled using a plastic hammer
Mount the ring pinion (with bearings) to the steering rack
Assembled in housing S/A .
Country • Light when driving the steering pinion
done in Ka.
Snubbing ring
SKICIHI
4. New, ÿ tie using SST and plastic hammer

Up
Assemble the BK oil seal.
snow 0931 0-87301 -000
Co • Grease the oil seal mounting part of the housing.
Prevent wreath from sticking.
Five . ÿAssemble the steering rack.
Trouble • Steering rack tooth flank and rack circumference
Apply Amix Long Life Grease to
do.
• When inserting the steering rack, SK" Co 082
Do not damage the shoe.

6. Adjust the steering rack blade as follows:
be.
1 . Tightening the rack guide spring cap
I[2 . Rack guide spring cap return

l••…reference value
4 5 Return 1 store
l
1.47 0.5 N m {15 5 kg cm} (without boots)
l… …reference value
1.60 Sat 0 _ 5 N m {16 S kg cm} (at the foot of the boot))
ÿ3] Mode measurement
(Pinion starting torque)
within the reference value
Four . lock nut tightening | re

tone adjustment
Loosen the rack guide spring cap Repeat steps 1 , Up
to 3 below,
Five . Preload confirmation
SKICI II
E-32
Steering
Key points of preload adjustment>
(1) Using a simple spinner , pull the ÿ rack guide stub

Tighten the lug cap to the specified torque.
(l[N) 1 2. 3 2. 0N m (Reference {1 25 20kg • crn}
J • Simple spinner (width across flats 17Dlll)
Next, return the spring cap to the reference angle.
vinegar.
ÿ 45 !
SKICl283
Use SST to check brake load (starting torque).

(2) Snow 0 961 6-87502-000
wet 1 47.1±49.1N•m {1 5 kg cm}
(3) Using SST and a simple spinner, ÿ hexagon nut

SST
Around 39.2 4.9 N m {400 50 kg cm}
Darkness 0961 7 -87201 - 000 (Width across flats 39mm)
(Reference J • Simple spinner (width across flats 17Dlll)
Trouble • Simple screw to prevent the spring cap from turning

Secure and tighten with a pinner.
(4) Next, use SST to apply the brake load (starting torque) again .
Check .
Snow 0 961 6-87502-000
Around 39.2±4.9N m {400 Sat 50 kg • cm}
7. Assemble ÿ rack end nuts (RH, LH) and ÿ steering rack No. 1 end S/A (RH, LH).
wear.
(1) Screw the rack end plug ÿ into the rack end ÿ. (For the rack end plug, use the larger flange.)
is the rack end side)
(2) Next, tighten the rack end ÿ to the steering rack ©.
(3) Secure the steering rack with Rack End Plugs®
(IUI) 56.4×7.4N•m {575 cc 75kg • cm}
SKICIOB6
E-33
Steering
8. ÿSteering rack boots (RH, LH)

Garden • The boots are different lengths on the left and right, so you can't get them wrong.
(Refer to the diagram on the right)
--RH : Total length about 181mm
I
LH: total length about 20 7mm
•• ÿ
SKICI087
9. ÿ Remove the steering tie rod end S/A (RH, LH).

and tighten the nuts to the specified torque. Alignment mark
9 .8• 4.9
(IlfJ {100 50 kg cm}N m
Worried spirit] • Alignment mark of steering rack No.
1 end and tie rod end made during disassembly
to match.
SKICI073
E-34
Brake
4 Brake
4-1 Brake inspection and adjustment
4-1-1 Brake pedal inspection and adjustment
(1) Pedal height check
1. Humidity for measuring the height.
of the brake pedal43°5nm
1
SKIC1090
(2) Pedal height adjustment

1. Remove the connector of the stop lamp switch .
2. Turn the ÿ nut of the stop lamp switch to allow the stop lamp switch to play.
3. Turn the stop lamp switch, tighten the nut that adjusts the .
4. ÿ height of the pedal and the nut (2), and attach the connector .
Around 1 8. 1 3. 4 N•m {1 85 35 kg • cm}
5. After adjusting the pedal height, check the pedal play and stop lamp switch lighting.
(3) Pedal play check

1. After stopping the engine, depress the brake pedal 4 to 5 times to release the vacuum in the brake booster .
state.
2. Lightly press the brake pedal with your finger until you feel , play
. and check the resistance.

some resistance,
SKI CIO III
(4) Pedal play adjustment

1. ÿLoosen the nut, ÿTurn the bush rod to adjust the .
pedal play .
2. After adjusting the free play , check the pedal height and stop lamp switch lighting.
E-35
Brake
(5) Pedal rest check
1. The parking brake lever was released during idling.
In the state where the pedal is depressed with a pedaling force of 30 kg and stopped
Measure the gap between floorboards.
wetness 105 nm or more
(From the center of the top surface of the pad to the floor panel)
and)
(When pedaling force is 30kg, engine is running)
SKICI092
4-1-2 Parking brake lever pull

inspection, adjustment
(1) Lever pullover inspection

1. After operating the parking brake lever 2-3 times,
Fully return the bar.
2. Slowly pull the parking brake lever until it clicks.
tsu 3 to 5 notches (operating force .
wetness 20kg)
(2) Adjustment of lever pull

Garden • Point the pull of the parking brake lever
Depress the brake pedal 2-3 times before checking
to eat.
1. Turn off the parking brake lever dust cover ,
Turn the adjusting nut so that the notch is at the reference value.
2. Check .
that there is no dragging of the rear brake . .
SKICI094
4-1-3 Checking the shoe lining thickness

(1) Shoe lining thickness check
1. B Remove the rake drum and check the thickness of the shoe.
wetness 5 nm (front wheel) , 4 nm (rear wheel)
Scrap 1 nm (both front and rear)
4-1-4 reservoir tank

(1) Liquid volume
1. Leak around reservoir tank and master cylinder

2. Remove.
the reservoir filler cap . , reservoir
Check that the liquid level in the tank is at the specified level.
wetness Must be between MAX and MIN .
SKI C1095
E-36
Brake
4-2 Removing and installing the pedal bracket and brake pedal
2-1 Preparations
Four -
Amix MP Grease
code, SKICll2
1. Drain
4-2-2 Workthe brake
before fluid from the master cylinder reservoir .
removal
2. Remove steering column Ay.
3. Remove instrument panel

(Refer to E. 3-2 (pageAy.
E-21))
4. Remove the connector of the stop lamp switch .
5. Remove the clutch cable from the clutch pedal.
6. Disconnect the vacuum hose from the brake booster .
7. Disconnect the reservoir tube from the master cylinder .
8. Remove the brake master cylinder.
|-T : 1 2
^^ ÿ:
8 3.0 {1 3rd - 8 Sat 3. o {130 30f ]
ÿ
®/
'' ,
, two, "' , \
ÿ®
ÿ ÿ
B
Construction disaster 1 earth 3 . 4 {1 life king order [ ]
I
ÿ// ®Kasumiÿ , ÿ'/'> :] ] ÿ ÿ
ÿ-@ <:/'\, ÿ
ÿ
ÿSupport Ay, pedal bracket ÿPin, w/ hole
ÿStay pedal bracket ÿBolt
ÿ
ÿ Stay Steering Column Upper ÿ Spring

ÿ
ÿ Booster Ay , Brake ÿ Spacer * : Non-reusable parts

ÿ Switch Ay, Stop lamp ÿ Bush Unit: N•m {kg•cmf
ÿPin, cotter ÿPedal S/A, brake
SKl CI l01
1. Install
4-2-4 Workthe brake
after master cylinder .
installation
2. Install the (Refer

reservoir
to E. tube to the
4-3 (page master
E-39) ) cylinder .
E - 37
Brake
3. Attach the vacuum hose to the brake booster . 4.
Attach the clutch cable to the clutch pedal. 5. Remove
the connector of the stop lamp switch . 6. Install the
instrument panel. 7. Install the steering column Ay.
(Refer to E. 3-2 ( page E-21))

8. Add brake fluid to the MAX reference line of the master cylinder reservoir. 9.
.
Bleed air from the brake system. 10. Inspect and adjust the brake pedal (Refer to
E. Section 4-1-1 (page E-35))
11. Make sure there is no brake drag .
E-38
4-3 Removing and installing the brake master cylinder

09737-87003-000
Bush rod clearance adjustment
GAUGE, BOOSKE BUSH ROD
Grease I Amix MP Grease

SktCt2t
< , , ,ÿ' , , ,
*
ÿ
Four
ÿ *
ÿ Cap, reservoir filler
|
ÿ Clip
ÿTube ÿTube ÿ
Reservoir
Consideration 9
ÿReservoir ÿ Reservoir
Ay , master cylinder
ÿ
ÿ ÿ Cylinder Ay , Brake master
ÿ
Unit: N m {kg cm}
SKIClll5
Brake
1. When installing ÿ brake master cylinder Ay,
Brake booster bush rod
Ru .
(1) The SST rod lightly touches the master cylinder piston.
Set it to the position where it hits.
snow 09737-87003 -000
SKI CII04
(2) Flip the SST and connect the rod of the SST and the bush of the booster .
Check the shrod .
clearance ”Clearance 0 11111
(3) If it is out of the standard, lengthen it with the nut at the end of the bush rod.
Adjust the height.
, I
SKICII06

1. Install meter Ay.
2. Install the instrument panel.
4. Add brake fluid up to the MAX reference line of the master cylinder reservoir . .
5. Bleed air from the brake system.
6. Make sure there is no brake drag.
E-40
Brake
4-4 Brake master cylinder disassembly and assembly 4-4-1 Preparations
Yushi
Tool 1ring
Snub Brake Fluid,
Expander Amix Rubber Grease
SKIC'"
c// ..: Amix Rubber Grease * : Non-

reusable parts
9/ //\ , s, '/>
///
/
/
/
^0 da/category
</' /\/
Iidaiÿÿÿÿ Ay, brake master set
Bok
Hole Snap Kima

Star Cylinder
ÿ Piston Ay , Brake master cylinder No.2 ÿ Ring 0
ÿ
SK1 C1107
4-4-3 Disassembly
points 1. Using a snub ring expander and a screwdriver,
remove the hole snubbing ring ÿ while the piston is
pushed in .•The hole snap ring cannot be reused. 2.
Remove the brake master cylinder No. 1 piston Ay .
remove
it.•Removethe pin straight so as not to damage Pist
the inner surface of the cylinder.
• Piston Ay cannot be
reused. 4-4-4 Inspection (1) Master
cylinder 1 . Check for scratches on the
inner surface of the cylinder . 2. Inspect
the cylinder for deformation or damage.
E-41
Brake
Use a snubbing expander and screwdriver .
1 Push in the piston and remove ÿ hole snap.
Assemble the spring.
E-42
Brake
4-5 Brake booster operation check
ÿ shape
Total` BBT- lTB

vessel
Pedal force meter

portable brake booster tester
Handled by Banzai Co., Ltd. Brake booster function check
SK1Cll5
4-5-2 Brake booster airtight function check

1 . Start the engine, and after about 1-2 minutes, stop the engine. good defective
the brake pedal with a pedaling force equivalent to normal braking .

Check the height of the pedal when the pedal is .
stepped on several times. .
( between 1st and 2nd , 2nd and 3rd
5 seconds or more)
SKICI IOI
4-5-3 Brake booster operation check

1. With the engine stopped, press the brake several times with the same degree of pedaling force.
Depress the key pedal and check the pedal height.

wetness No change in pedal height
2. From the above state , start the engine while depressing the brake pedal .
and check for changes in pedal height.
" When the engine starts, the pedal goes in a little.
SKICI IIO
4-5-4 Brake booster load seal function check

1. While the engine is running, depress the brake pedal and
Stop the engine and hold for 30 seconds to measure the change in pedal height.
Inspection to.
" There is no change in the pedal height.
SKICI III
E-43
Brake
4-5-5 Inspection with a portable brake booster tester
(1) Installation points
1. Remove the meter Ay , connect the portable brake booster tester as shown in the diagram, and
Bleed air.
pressure gauge
SKI Cll 12
(2) Inspection
ÿ Brake booster airtight function check
1. Start the engine, and when the negative pressure gauge shows 66.7kPa (500D111Hg), stop the engine and measure the negative pressure.
There is no drop in negative pressure for 15 seconds after the engine has stopped.
2. Start the engine, step on the brake pedal with a force of 20kg, and when the negative pressure gauge shows 66.7kPa (500D111Hg), start the engine.
Stop the gin and measure the negative pressure.
Wet air pressure drop within 3.3kPa (2511111Hg) for 15 seconds after the engine is stopped.
ÿ No-power operation check

1. Stop the engine, set the negative pressure gauge to 0 , and check the relationship between pedal force and oil pressure.
Around
Pedal force [N (kg)] Liquid pressure [MPa (kg/ai)]
98 (10) o.7 (8)
294 (30) 3.6 (37)
SKICI II
2. Start the engine and set the negative pressure gauge to 500D111Hg.
3. Stop the engine and check the master cylinder oil pressure at each pedal force.
wetness
Pedal force [N Liquid pressure [MPa (kg/ad)]
(kg)] 49 (5) 1.5 (16)
98 (10) 147 3.3 (33)
(15) 196 (20) 5. 0 (51) 6.
5 (66)
SKICl l7
E-44
Brake
4-6 Removal and installation of brake booster
shape
09737-87003--000
•ÿ Bush rod clearance adjustment
GAUGE, BOOSTER BUSH LOT
SST
Fat I Amix MP Grease

SKICll3

1. Drain the brake fluid from the master cylinder reservoir .
2. Remove steering column Ay.
3. Remove the instrument panel.
4. Remove the combination meter .
5. Remove the master cylinder.
6. Remove the pedal bracket Ay.
tsu /' 'ÿ | T: 1 2.8 3 .o{130 Sat 30}]
/
®
,''
Of which 2.8 soldiers 3.0 {1 30 orders
\\...- ® 2 . 8 Sat 3 .o{ 1 30 3
ÿ Support Ay, pedal bracket

ÿ Booster Ay , brake
SKICII02
E-45
Brake
4-6-4 Inspection
(1 ) Vacuum hose (check valve)
1. Use a mighty bag , etc. to remove the point of the vacuum hose.
perform an .
examination ” Booster sideÿ Engine side …Ventilated
Engine side ÿ Booster side… No ventilation

2. Replace the vacuum hose if it is defective. .

1. Install the master cylinder .
2. Install the pedal bracket Ay.
3. Install the combination meter .
4. Install the instrument panel.
6. Add brake fluid to the MAX reference line of the master cylinder reservoir.
8. Make sure there is no brake drag.
E-46
Brake
4-7 Brake booster disassembly and assembly

4 -7 -1 Preparations
Boothcoupode disassembly and
s Sho 09753-87701-000 Tool SIA, brake booster

Overhaul
assembly
Removal and installation of oil seal
s 09608-2001
2-000
(09608-00030-000)
(09608-00080-000) I Removal and installation of oil seal
Tool set Binion (09608-03020-000) Front Hub & Drive
ÿ
bearing
Oil I Silicone grease

SKICI IB
nine
13 sand/]
bu'/
/` ÿÿ ofof
stomach
ÿ
If—|ÿ
// //
/ * : Non-reusable parts
ÿÿ1—Shamefulness ...ÿ Clevis master cylinder

ÿ ÿ Piston booster
ÿ
push rod ÿ Element ÿ ÿ air cleaner

... ÿNut Separator ÿ Key ÿ air cleaner
....... ÿBody S /A, Booster No.1 S/A, valve stopper
ÿ Spring, booster piston ÿValve S/A, booster air
Return ÿ Boots
ÿScrew Rod Adjust ÿRod Booster Piston
ÿ ....... ÿSeal , boost turbo day No2
ÿDisc Reaction
ÿ ... ÿ Body S/A Booster ,No.2
ÿ
ÿ Diaphragm, Booster
SKICl l13
E-47
Brake
4-7-3 Points of Disassembly
1. Set the brake booster to SST, ÿ booster
Remove ÿ booster No. 2 body from No. 1 body. Country
09753-87701 -000
SKi C9194
2. Using SST and press, ÿ seal, booster port

Remove Day No. 2.
unit · Removed seals cannot be reused.
bower 09608-03020 - spider
09608- 00080 - spider
09753-87701 -000 component ÿ
B
1. Use SST and brace to install new ÿ seals, booster
Install body No. 2.
ÿ 09608-03020-ooo@ 09608
-00030-monument
2. Use SST to install ÿ booster No. 2 body

be.
four 09753-87701 -000
3. ÿNuts ÿMaster
rod cylinder bush
Temporarily .
master
tighten the levis. cylinder push rod
Screws and nuts should be tightened to the specified torque after pedal adjustment.
Tighten with
(Refer to E. Section 4-1-1 (page E-35))
Spring 1 2. 7 Sat 2. 9 N m {1 30 30 kg • cm} SK1 C1114
E - 48
Brake
4-8 Front brake drum removal and installation
ÿ Amix Brake Grease, Amix Rubber Grease
Grease I Brake
instrument torque fluid
wrench
SKICll9

1 . Jack up the vehicle.
4. Separate the brake tube and brake wheel cylinder Ay.
Tÿ ÿ
ÿ : Amix Long Life Grease
ÿ*Non-reusable
: Amix Rubber parts
Unit: N•m]kg•cm}
Grease
: ... ÿ Cap, front hub grease

... (2) Pin, cotter
poverty
... ÿ Cap, front wheel adjusting lock
... ÿ Nut ÿ Hexagon
... ÿPairing
saddle ... ÿDrum brake ÿ
ÿ -, ÿ Spring shoe hold down

ÿ
ÿPin , shoe hold down spring

ÿ Spring ÿ Shoe tension
clever ÿ
:
,
Ay, Front brake
death
ÿ Cylinder Ay, front wheel brake (No2)
ÿ ÿ Cylinder Ay, front wheel brake (No1) ... ÿ Plate S/A, brake
backing ÿ Spring, adjuster castor lock ÿ Front
Go game
child ÿ Lever automatic adjusting
ÿBolt ...
ÿ
ÿ Front wheel cylinder adjusting

ÿNut ÿ Front wheel cylinder adjusting
SKI C1 1 20
E-49
Brake
4-8-4 Inspection
(1) Checking the inner diameter of the brake drum
l. Inspect the inner diameter of the brake drum and check if there is significant uneven wear.
If so , grind or replace the brake drum.

wet 1 8011111
Bandit 1 81 11111
(2) Inspection of shoe lining thickness

1. ,
- Check the thickness of the lining.
Replace the brake shoes if they are unevenly worn .
wetness 5 11111
ÿ 1 11111
Trouble • In order to prevent one-sided effect when exchanging the brake shoe ,
.
Therefore, replace both the left and right sides of the vehicle as a set.
SKIClt 22
(3) Contact between shoe lining and brake drum

Rough inspection
1. Apply chalk to the inside of the brake drum , brake

and rub it against.the shoe .
polish .
SKI C1123
(4) Wheel cylinder inspection

.
1. Inspect the wheel cylinder for corrosion, damage, etc.
(5) Backing plate inspection

1. Inspect the backing plate for wear and damage.

1. Steering knuckle, ÿ plate S/A, brake bar
Apply liquid gasket to the mating surface (whole circumference) of the packing.
Ru .
Around the corner] •Brake mounting port holes (4 places) Heseal agent
Sonokuchi Daihatsu Bond Na. 4
2. Before installing the ÿ brake drum, check the inner diameter of the drum and the brake
,
Measure the outer diameter of the rake shoe and the difference is about 1 plate.
Up to ÿ Adjusting nut Front wheel SKICl 1 24
Adjust by turning the cylinder.

3. Install ÿ brake drum.
E-50
Brake
<How to install the brake drum>
(1) ÿ Tighten
specified
thetorque.
nut to 42.2
the 4.ON• m
{430°40kg cm}nut(2)
about
After45ÿ °loosening
, rotateÿthe
brake
the drum
back and forth 2 to 3Check
times,the
andfit.ÿ the bearing will fall.
(3) Fit the box of the box wrench to the nut, hold the box and tighten the nut. (Reference)
• Do not tighten the nut directly with your fingers, as this will result in insufficient tightening force.
(4) Install the ÿ cap, front wheel adjusting lock, ÿ pin and cotter, ÿ cap, fill the front hub grease with
grease and install.
Wakunao Amix MP Grease (14g)
4-8-6 Connect the work

1. brake tube to the brake wheel cylinder after installation.•Tighten
the union nut
tubetemporarily
comes in close
by handcontact
until with
the flared
the seat
part, and
of the
then tighten it to the specified torque.
Spring 1 5. 2 Sat 2. 5N · m 2. Add brake fluid to the MAX reference line of the reservoir .
{1 55
3. Bleed air from the brake system. 4. 25kg
Check cm}for brake fluid leakage. 5. Depress the brake pedal
and check that you hear the auto adjuster 's operating sound (clicking sound), then depress the brake
. sound stops. Install the front wheel . Approximately 7. Check
pedal repeatedly until the operating
brake drag. 8. Jack down the vehicle.
6.
1 03.0 Sat 14.7N m {1 050 1 50kg cm}
E-51
Brake
4-9 Removal and installation of rear brake drum
4-9-1 Preparations
|\ shape letter Model Product Name for road
Ni
0951 1-87202-000
s ÿ —- Stopper, brake drum
Whirl-stop of brake drum
T. Remove brake drum

Puller, Front Hub & Drum
09510-87301-000 _
Instrument G) Wrench
Oil Amix Brake Grease . Amix Rubber Grease . brake fluid

SKICl20

4. Separate the brake tube and brake wheel cylinder Ay .
Hundreds of sadness L_ _”
ÿ : Amix Brake Grease

ÿ : Amix Rubber Grease
^ ,
/ ,
ÿ Pin, cotter /
,.,ÿ ÿ) Nut
,.,
ÿCastle
(3) Drum 5/A, brake
ÿ Spring. Shoe hold down
\ ,,
® Pin, Shoe Hold Down Spring @, ÿ ,
ÿ Spring. tension
ÿ Spring. tension
((1) Spring, tension
® Shoe Ay, Brake No. 1 A@ spring, torsion
, ,B
ÿ Shoe Ay , Brake No. 2 ÿ Strut ÿ ÿ Pin, automatic adjuster lever * : Non-reusable parts
Leper , ÿ Cylinder Ay
ÿ , Wheel
Parking brake shoe A @ Plate parking brake shoe ÿbrake backing Unit: N•m 1 kg cmf
ÿ Pouts
Brake Rear ÿ Piston , Wheel le ÿ wheel cylinder
brake cylinder
ÿ ÿ Latch. automatic adjuster ÿ Coup cylinder
ÿ ÿ Leper . automatic adjuster ÿ Spring compression
SK1C1 1 30
E-52
Brake
4-9--4 Main points of removal
1. Using SST, remove the ÿ castle nut.
\\\one
Snow 0 9511-87202-000
2. Using SST, remove ÿ brake drum S /A .

Darkness 0951 0-87301-000
SST
SKICll37
4-9-5 Inspection
(1) Checking the inner diameter of the brake drum
, find significant uneven wear.
1. Inspect the inner diameter of the brake drum to
If the metal is damaged, the brake drum should .

be ground or replaced
80nm .
Straight 1 81nm
SKIC1 131
(2) Shoe lining thickness check

lining, and
- Inspect
1. If thethe
shoe
thickness
shows of the Below limit or
excessive uneven wear, it is time to replace the .
brake shoe . 4 11111
111111
In order to prevent one-sided effect when exchanging the brake shoe ,
Therefore, replace both the left and right sides of the vehicle as a set.
SKtClt32
(3 ) Shoe lining and brake drum contact

Tear check
1. Apply chalk to the inside of the brake drum. , brake
.
polish .
`` There is no significant hit failure.
Trouble • Wipe off the chalk after inspection .
SKICll33
E-53
Brake
(4) Wheel cylinder inspection
1. Check the wheel cylinder for corrosion and damage.
(5) Backing plate inspection

1. Check the backing plate for wear, damage, etc. .

shoe
. Attach
1. brake Attach the following parts to the side (reading side).
leper
16] Torsion spring
s ÿOautomatic adjust latch

Garden • Use a new type C washer.
SKlC""
2. Rear axle housing and ÿ backing plate

Apply liquid gasket to the mating surfaces (whole circumference).
Troubleshooting] • Brake mounting port holes (4 places) Heseal agent

Ko Sonoguchi Daihatsu Bond No. 4
SKIC1135
3. Using SST, attach the ÿ castle nut.

rn!] 0951 1-87202-000 ÿ
ÿ
D
SKIC1138

1. Connect the brake tube to the brake wheel cylinder .
Children] •Tighten the union nut temporarily by hand until the flared portion of the tube comes in close contact with the seat , and then tighten according to the regulations.
Tighten with torque.

Around 1 5. 2 2. 5N m {1 55 25kg • cm}
2. Add brake fluid to the MAX reference line of the reservoir.
4.Check for brake fluid leakage .
Five . Install the rear wheel .
Around 1 03.0 14.7 N m {1 050 1 50 kg cm}
6. Depress the brake pedal 2-3 times to operate the shoe clearance adjuster mechanism to adjust the shoe clearance.
Adjust to proper condition.
7. Check brake drag.
8 . Jack down the vehicle .
E-54
Brake
4-10 Parking brake removal and installation
4-1 0-1 Removal and installation procedure
Todo 1.5 { 55 Saturday Day |
Five]
2]
/ÿ
40,000 yen and 5,500 yen]
Shimotsuchi 7 Summoning Washi]

f or
Iÿ
Color 5.4 Sat 1.5 {55 King [Shout
9:JJ))hlPl
[T: 5.4 Sat 1 .5 {55 Shi 1 5_U
Freon
B door
ÿCover ÿ Parking brake lever dust

ÿHandle Ay, Parking brake control
ÿ Cable Ay, parking brake (RH)
ÿ Cable Ay, parking brake (LH)
ÿ Cable Ay, parking brake w/equalizer
Unit: N•m { kg cm f
SKICl 140
4-1 0-2 Work after removal

( Refer
.Adjust
to the
E. Section
pulling margin
4-1-1 (page
of theE-35))
parking brake lever 1 .
E-55
built-in adjustment
1 Built-in adjustment
1 -1 Around the front panel
Department rank Gap Difference between left and right Step Deviation
ÿ : Side Panel X Quarter Panel 2. 0 1.o 1.5 or less ÿ 1.5 1.3~3.0 l.
ÿ : Front Panel X Side Panel 5 1.5 or less 0 1.5 ÿ: Side panel X
front panel center cover (upper) 4. 5 1.5 1.5 or less 0 1.5 4. 7 1.5 1.5 or less 0: l: s1. 5 ÿ: ÿ : Front
bumper x front panel sensor cover (central part) 28. 2 Saturday 2. 0 ÿ:
(beneath)
” 2. 0 or less
(both ends) 2.3 1.5 1.5 or less

ÿ : Front bumper X side panel
” 5.6 1.5 1.5 or less
ÿ : Front bumper x front fender lower 1.5 or less 1.o or less
SK1BIOOI
F-1
built-in adjustment
1 -2 Around the front door
200mm
200mm
400mm
Department
rank Gap left/ right difference Step Deviation
ÿ : Front door X side panel 4. 8 1.5 l.5 or less 1.5 or less
ÿ: Front door X quark panel (lower front side) 4.7Sat 1.5 1.5 or less 1.5 or less
ÿ: (part of the locker ) 4.5 Sat 1.5 2.7±l.5 1.5 or less
ÿ: ÿ:
”
II (Rear) 4. 4 Sat 1. 5 l.5 or less 1.5 or less
(Lower rear side of frame ) 5. 4 1.5 or less 1.5 or less
ÿ:
” Earth 1.5 ( Upper rear side of 1.5 or less 1.5 or less
ÿ:
” frame) 4. 2 1.5 (Upper side of 2.0 sat 1.o 1.5 or less
ÿ:
” frame rear curved) 4. 2 1.5 (Upper 2.0 1.o 1.5 or less
ÿ:
” front side of frame) 5. 2 1.5 1.5 or less
” (Upper
1.5 ( Lower front side of frame) 3. 0 1.5 ÿ: ÿ : Sidefront
panelside of frame
X Front ) 4. 1
fender 1.5 or less
”
lower ÿ : Head head lamp cover x side panel ÿ: front bumper x side panel
less than 10
l. 0~3.8 1.5 or less

5.6 1.5 1.5 or less
SK1B1002
F-2
built-in adjustment
1-3 Around the deck side
<B type> < D type> <R type>
Department rank Clearance Left/right difference Step Deviation
ÿ : Quarter Panel X Rear Gate Cover ÿ : Rear Floor X Rear 6.0 Sat 1.5 1.5 or less
Gate Cover (Front) ÿ: (Rear) ÿ : Side Plate X Quarter Panel 4.7 Sat 1.5 1.5 or less
ÿ : Side Skirt x Side plate ÿ: Side skirt x Rear gate (front)

cover 4. 6 sat l. 5 L.5 or less
”
ÿ: (Rear) ÿ: Tilt resin panel X Quarter panel ÿ: Tilt resin 6. 0 sat l. 5
”
1.5 or less
panel X side skirt 2.0~3.0 less than 10
0~1.6 1.5 or less
4. 6 1.5 1.5 or less

” 6. 0 1. 5 1.5 or less
0~1.5
SKIBI003
F-3
built-in adjustment
1-4 Deck rear area
ÿ
ÿ
< B type> <D type> <R type>
tsu up
pu
0.7mm
7.m
ÿÿ Combination lamp :3.5mm rn : ÿ{: n

rCombination 3.4 mm
3.1
ÿ part cross section ÿ part cross section ÿ part cross section
Department rank Clearance Left/right difference Step Deviation

ÿ: Around the rear combination lamp (B quipe) ÿ: Refer to above diagram 1.5 or less 1.5 or less
(D.R type) ÿ: Around the back up lamp (D.R type)
” See above diagram 1.5 or less Refer
to above diagram
1.5 or less
ÿ : Rear skirt X Side skirt ÿ : Tilt resin 4.0 Sat 1.5 0~1.0 1.5 or less
panel (side) x Tilt resin panel (rear) 5.0 Sat 1.5 0 ~1. 0 1.5 or less
ÿ : IJ skirt X tilt resin panel 0~3.0
SKIBI004
F-4
built-in adjustment
1 -5 Bumper Guard & Roll Bar
front panel center cover roll bar
guard Aori resin panel
ÿ part cross section ÿ part cross section
Department rank Gap I Left-right difference I Step difference I Deviation
ÿ :Front
ÿ: Roll bumper
bar X tilt resin
guard X panel
front panel center cover 5.0 1.5 1.5 or less 3.0~5.2
SK9 B9005
F-5
front door
2 front door
2-1 trim related, Removal of glass and lock , attachment
2-1 -1 Prepared items
ÿ shape letter part number, Product name for road
city
sales
tool 'g remover , clip

For clip removal
Oil Amix MP Grease For coating each sliding part
handwriting
For glass mounting, scratch prevention,
soapy water, protection tape, butyl tape
other
For installing service hole cover
SKIBIOI
C.
ÿPort S/A, front door trim ÿ light a

....ÿ Cover ÿ ÿ Front door service hall ÿ light ''
Weather strip Ay, front door glass, inner so, one
ÿGlass S/A, front door, light
C.
ÿ Run ÿ front door glass
ÿRegulator Ay, front door window ÿ light
ÿ Frame S/A, front door rear lower ÿ light (2: Clip position
ÿ Lock Ay, front door, light
ÿWeather strip Ay, front glass, outer
ÿFrame S/A, front door front lower ÿ light
S1<1 B1006
F-6
front door
Five]
( ) : Clip position
ÿBoard S/A, front door trim ÿ Left

ÿÿ Cover, front door service hall , left
ÿ Lock Ay, front door, left
ÿWeather strip, safety window, upper, left
ÿGlass S/A, front door ÿ Left
SKIBl007

1. Outer view -Mirror tuning
.
Align the mark on the stay with the mark on the seat first, then
adjust the
SKIBl008
F-7
front door
2. Front door service hole cover
(1) Stick the butyl tape along the groove of the panel to the position shown in the figure below without pulling it.
(2) When attaching the service hole cover , firmly hold the butyl tape attachment area.
(3) If the service hole cover is torn, it may cause water leakage, so be sure to replace it.
SKI BI009
3. Window regulator handle

Install so that the angle shown in the right figure is obtained when the glass is fully closed.
SKIBIOIO
F-8
front panel center cover
3 Front panel center cover

3-1 Removal and installation procedure
ÿ ÿr): Clip position

2
ÿ cover _, spare wheel

ÿSpare wheel
ÿ Carrier S/A, spare wheel , No.2
... ÿCarrier Ay, Spare wheel
ÿ Cover S/A, front panel, center
SKIBIO II
3-2 Points of installation

Spare wheel carrier
Country •Because there is a vertical direction, assemble as shown in the right figure.
that
wide
I
)I
is narrow
SKIBIOl 2
3-3 Work after installation

Country · Carry out building adjustments.
F-9
side panel
4 side panels
4-1 Work before removal
1. Remove the front panel center cover .
2. Remove the headlamp Ay .
A.
ÿ
mouthful
', '/ 9.@
, i)
®——
........(1) Panel S/A, front side

SK1B10l3
4-3 Main points of removal

The top edge of the side panel is the windshield glass mode.
Since it is inside the molding, take care not to damage the molding.
remove it.
SKI BIOl4
F-10
side panel
4-4 Points of installation

.
1. Put it inside the fender from the bottom side of the side panel
[Reference] - Place the rear lower stay under the door hinge.
Garden • Work carefully so as not to damage the body .
.
SK1B1015
2. When inserting the upper edge of the side panel into the inside of the windshield glass molding, attach it with a bamboo spatula, etc.
Kick.
around the time Work
carefully so as not to damage the molding and podee .
• Assemble the weather strip and front ventilator as shown below.
front floor side
front panel
/outside
Front
AA cross section
Weatherstrip, front ventilator
SKIBIOl6
4-5 Work after installation

1. Install headlamp Ay.
2. Install the front panel center cover .
around the time Carry out building adjustments.
F-1 1
Bumper & bumper guard
5 Bumper & bumper guard

5-1 Pre-removal work
1. Remove the front panel center cover . (Front bumper and front bumper guard
when detaching)
2. Remove the rear skirt . ( When detaching the rear guard bar)
5 -2 Removal , installation procedure
3
.
ÿ Bracket, front bumper guard
ÿGuard set ÿ front bumper ÿ

ÿCover ÿ front bumper
ÿCover ÿ rear body floor ÿ Rear
ÿ Bracket ÿ Rear bumper arm mounting

ÿ Bracket ÿ rear bumper bar
ÿ Guard ÿ rear bumper
SKIBIOl7
5-3 InstallationAfter work

Garden • Carry out building adjustments.
F-12
Tilt & Tilt Resin Panel & Roll Bar

6 Tilt & Tilt Resin Panel & Roll Bar
ÿPanel , rear body side

(2) Panel, rear body data tail gate
ÿCover Side Upper Panel End
ÿCover ÿ rear end post
ÿFrame ÿ rear guard
ÿFrame Ay , rear body guard
ÿBar Ay, roll over
SKIBIOl 8
F-13
side skirt & rear skirt

7 Side skirt & rear skirt
2]
* Rotate with your finger.
ÿ Plate ÿ Rear fender front side
ÿCover ÿ Rear body floor side
ÿCover ÿ Rear body floor , rear

SK!B1019
F-14
instrument panel
8Instrument panel
8-1 Work before removal
bure Remove the cap of the brake master cylinder reservoir . (When removing the right instrument panel)
Trouble • Make sure that no dust or the like enters the reservoir .
8-2 Removal and installation procedures
`'
ÿPanel instrument side, left
ÿ Cap, reservoir filler
ÿPanel S/A, instrument
ÿ Nozzle Ay, defroster
'
'' '
SK1 B1020
9 seats
9-1 Removal and installation procedures
]
ÿ ÿÿ:
ÿHeadrest Ay, front seat

ÿBand
ÿ Cushion
ÿ engine service hole cover support
ÿBack Ay, front seat ÿCover, ÿ light

ÿ:I
engine service hall main ÿ light
ÿ Mat ÿ Center floor, right Palm
ÿ Track Ay, front seat light inner

history
ÿ Slider ÿ front seat rail and @
ÿ Cushion Ay, front seat , light

SK9B9029
F -15
seat belt _
1 0 seat belt
1 0-1 Removal and installation procedure
:: ÿ
ÿ
2]
FR
FRÿ Tomoe location
ÿ] Circular Riri
Do not ride up
Plan view of the bad part
/ standing, , on top Mege Vina One doko To
'\ ||\
I' Hidden] Partial view
\I ' \|
Whole bolt | T: 40.7 Sat i2.3 {41 5 Sat 1 25} |
ÿCover ÿ seat belt retractor

....ÿBelt Ay, front seat outer, light Unit: N m {kg cm}
....ÿBelt Ay, front seat inner, light
SK!B1022
1 2 Points of removal
0-Garden Disconnect the seat belt warning harness connector .
1 0-3 Retractor inspection

1. ELR winding, lock inspection
•When you pull the belt slowly and release it, check that it winds up smoothly.
•Check that the belt locks when the belt is pulled suddenly.
2. ELR lock start tilt angle check
When the retractor is gently moved from the installed state, all
The belt must not lock within 15° against the , and 45°
direction
to confirm that the lock state is maintained.
Country · Do not disassemble the retractor .
1 0-4 Installation points

Trouble • Install the anchor in the direction shown in the figure. Also, do not ride on the , Whirl-stop
location beads.
•Be sure to assemble the belt as shown in the figure.
•Connect the harness connector for the seat belt warning .
• The belt should be pulled out and wound up smoothly when installed.
F-16
Roof head lining
1 1 Roof head lining

1 1-1 Removal and installation procedure
2]
ÿ Trim ÿ Roof headlining. No.1

ÿHeadlining No.1 ÿ roof ÿ
SKIBI024
1 1-2 Important points for installation
Apply the adhesive to the hatched area in , roof headliner

the right figure, press it radially from the center of the ring, and stick it.
FR<:;:::i
SK1 B1025
F-17
Lamp related
1 Lamp related
1 -1 head lamp
2
1
.
Four
/ ''
'''' ....ÿ Ring , headlamp ornament
ÿHead lamp
ÿ Head lamp bracket
ÿHead lamp cover
SKI HOOOI
1-1- 1 Removal and installation

Garden • : When removing the ring, be careful not to remove it according to the following procedure or the nail will break.
(1) Remove the tapping screw.
(2) Push the headlamp back. (near the A or B part of the ring)
(3) Insert a ÿ screwdriver into the gap between the headlamp and the ring and push the cover outward from the inside.
Remove the claw from the cover.
Ring headlamp retainer

head lamp
head lamp
Part A Part B
I
ÿ ring head lamp Retainer cover
I
La Tapping screw
Rin
driver
SKI H0002
1-1-2 Work before headlamp optical axis adjustment

1. 2. Fill up with gasoline, oil, and water, and use smooth .
tires, tools, and a jack. Mounted on the position of the
3. Shake the vehicle up, down, left and right to allow the suspension to settle into normal condition.
.
4. Keep the engine speed above 1500rpm
G-1
Lamp related
1 Functional inspection (optical axis adjustment)

1-1-3
Position the headlamps directly against the screen so that they are on a watery floor and 3 m from the screen .
put it in the corner.
2. Set the reference point of the head lamp focus on the screen. 26mm minus the center height “H” of the head ramp
Draw the height on the screen as an adjustment line. Set the center vertical line of the left and right head lamps on the screen,
Find the viewpoint "F" with the adjustment line.
3. Turn on the headlamps in the upper beam state and adjust so that they come to the intersection point "F" on the screen.
adjusting screw.
4. After adjusting the focus, use the lower beam to irradiate the lower left corner.
left right
and
door mm
ÿ_
!
Engineering
F.
H: Headlamp center height

SKI H0003
G-2
Combination meter
2 Combination meter
2-1 Removal and installation
Kan
ÿ
A.
rJ
(1) Panel instrument side left

ÿPanel instrument
ÿCombination meter
ÿ Windshield
ÿ Window plate
ÿ Speedometer & fuel gauge
ÿ Circuit plate
SKIH0004
G-3
Combination meter
2-2 Circuit diagram
-'Four
one
| ÿ
General
-
_ A_
ÿ chia
i l vinegar_
Oy
Meter terminal layout
SKIH0005
2-3 Speedometer
2-3-1 On-board inspection
Use a speedometer tester to check meter indication error, pointer deflection, and totalizer .
term eye Meter display (error) preparation thought
Instruction error Within +15%~-10% At actual speed (tester indicated speed) 40km/h or more
Guideline Shake Sat Within 2 km/h

SKI HOOi
Sono Kosen]
•Insufficient air pressure and wear of tires will lead to meter reading error. Pointer deflection is caused by cable
There are many things.
G-4
Fuel Gauge & Water Temperature Warning Light
3 Fuel Gauge & Water Temperature Warning Light

3-1 Fuel gauge
1. Remove the connector to the fuel sender gauge .
2. When the ignition switch is turned "ON" , Make sure the needle on the fuel receiver gauge indicates E.
.
Ground the green-yellow wire of the vehicle wiring harness side connector of the fuel sender gauge connector.
. ,
When the ignition switch is turned to the "ON" position, the pointer of the fuel receiver gauge rises little by little.
Check that it shows a rising F. However, it will take some time for the gauge pointer to settle down.
3. When the ignition switch is turned "OFF" , The needle on the fuel receiver gauge continues to indicate F.
To verify that .
3-1-1 Individual inspection

(1) Fuel receiver gauge
From combination meter Fuel receiver E]
Remove gauge . Removethe fuel receiver gauge

vinegar. Measure the resistance between each terminal of the fuel receiver gauge
do.
measurement terminal Resistance value (0)
® (IG C±) terminal) to ÿ (ground) about 250
® (IG C±) terminal) to ® (gauge terminal) about 90

SKt HOOOS
® (gauge terminal) to ÿ (ground) about 160
SKIH002
(2) Fuel sender gauge

Make sure the float moves without sticking . of float
Between the terminal and the body when the position is changed between points E and F
.
measure the resistance of
Position Float position (DID) Resistance value (a)
point F 55.2~6 1.2 1 to 5 He
1 20. 8 28.5~36.5
`
1/2 point
point E 181.5 ~ 187.5 1 13 ~ 1 27 `

j [
SKI H003 ]
of
.[-. ÿ
point E
SKI H0007
3-2 Water temperature switch

Show the characteristics of the right figure.
ON
OFF
/ 1 ÿ ÿ
Teri Si Soo within c
ÿ
SKIH0008
G-5
buzzer
4 Puzzer
4-1 Forgetting to remove the key warning buzzer function
If the key is inserted with the ignition switch " ACC " or in the lock position ( key switch " ON" and
) When you open the front door , A warning buzzer sounds .
G-6
Wiper
5 Wiper
5-1 Front wiper
5-1-1 Removal and installation
: One ``Summer ÿ Five]
ÿ Cf 9 Four
J.
ÿNut ®
ÿ Arm & Blade
ÿRubber
ÿMotor Ay
ÿLink Ay
SKI H0009

Bunnel instrument side left , Remove the panel instrument.
G-7
Wiper

Operate the wiper motor to the automatic stop position. 2. Set
the gap between the tip of the blade ÿ and the weather strip
rubber to the position shown in the figure, and assemble the arm and blade .
SKI HOO,.
G-8
Maintenance standard value
1 Maintenance standard value

1-1 engine
Engine adjustment reference value (EF - CK)
Term -] 1 ------ 1 - Niro: one set EF-CK
Id) Re rotation speed (rpm) 950 Sat 50
points (%) fire Time term (0/BTDC) 5 Sat 2/950
ah stomach do ) Le co l. 5 magazines: g
ah stomach do J-Les HC (ppm) 900 or less
Fast idle speed (25°C) (rpm) 2,000 300 (no adjustment required)
Throttle positioner touch speed (rpm) 1, 800 soil 100

Cylinder head 53. 9 4. 9 {550 Sat 50}
Tightening torque
Intake manifold 19. 1 Shi 3. 8 {195 Sat 39}
(N m {kg cm})
exhaust manifold 25. 0 Sat 5. 0 {255 Sat 51}
Warm IN 0. 25 Sat 0. 05
(reference value) EX 0.30 0.05

Valve clearance (111D)
IN 0.18 Sat 0.05
cold question
EX 0.25 Sat 0.05
Timing belt tension (N{kg}) (at 5mm deflection) 24. 5 4. 9 {2. 5 0. 5}

Oil pan (LOW/FULL) 1.7/2.7
Lubricant (£) Full amount 3.1
Remaining amount when drain is discharged 0.3
messenger for Oh i ) Le 5W-30 (equivalent to SF)
Reservoir tank (LOW/FULL) 0.15/1.0

Cooling water volume ( £ )
Total capacity (excluding reservoir tank) 3.3
Water valve opening pressure (kPa{kg/ crd }) 88 Sat 15 {0. 9 Sat Q. 15}
Antifreeze mix ratio (cold regions)

B (%) 30 (50)
V-belt deflection (111D) (readjusted, 98N{10kg} pressurized) 6.0~9.5

Plug gear knob (DD) Air conditioner idle-up speed (rpm) 0.9~1.0
1 , 300 sat 50
SK1 H101
H-1
Capletor specification (EF-CK)

Item
engine type EF CK
work _ Ho Pin inner diameter (1) pin/ outer tf,45
engineer Ho diameter (1111) (4) diameter (1111) tf,50

po ah Diameter ef,28
A The Ben Chiyuri diameter (on) <f,23

Sumo J Reben Chiyuri nozzle J ¢9
me stomach ,of diameter (an) ¢2.6
me stomach Engineering / Engineering tsu Diameter (DID) ¢1.15
Su Ro Ji engineering tsu Diameter (DII) Diameter 90. 49

two do J recipe (1111) Oil level ( from top ¢1.4 (with side hole)
Flow of body ) (DD) 26 soldiers 1
Li Head clearance (DID) 1.9 Sat 0.1

Float adjustment
Self-weight dimensions 14.6
( DID ) Mixture adjust screw set position (return amount from fully closed) (rotation) closed about 3.5
all (°))(° corner Every time 15. 5 1

Throttle valve
all open corner Every time 90 5
all closed corner Every time (0) 11. 5 Sat 1

choke valve
all open corner Every time (0) 90Sat 3
a'noro _ Opening degree (from choke valve fully closed) (°) 28 Sat 2
SKIHI02
Lubricator
Oil pump (EF-CK)
term eye Reference value Usage limit Apply
Relief valve opening pressure (kPa{kg/ai}) I 451~529 {4.6~5.4} 100ÿ, 4,000rpm

SKIHI03
H-2
1-2 drive
Oil type and capacity
term eye full capacity oil fat
manual transmission 1. £1 Amix Ga Oil SAE75W-85 (API Classification GL-3)
rear differential o.8.e _ Amix Hypoid Gya Oil SAE90 (API Classification GL-5)
SKI H104
clutch
term Item Standard value Usage limit Summary
Clutch pedal play Beauty 15~25
shake Ten
clutch disc
(mm) ( ua ) Lining wear 0.3
(DD) Clutch force 0.1
SKIHI05
manual transmission
term eye pick up required
Oh i J-Les
level 0~5DID
1 Standard value Usage limit I Filler under the plug
from the surface
SKI HI06
Propeller shaft
term eye Reference value Usage limit Summary
Re (m) 1. o
|
SKI HI07
Differential
term eye Reference value Usage limit pick up required
|
i J-Les
level J-Les
0~5DID Phila brag From bottom
SKIHIOB
H-3
1-3 chassis
Suspension
term Item Reference value Use limit Remarks
Bok b `./ 1.0 2.0 Left-right difference 1D111 or less
(1111) Camber angle ( ÿ) 0° 10' 45'

Front wheel alignment
Caster angle (ÿ) 7" 15'Sat °
Kingpin angle (° ) 1 1 2° 39'Sat 1°
inside 39 °50' F2 °
Evening ear cutting angle (0)
outside 32° 30'Sat 2
Side slip (DD) centre Long In 5- Out 5-

SK1H1011
Steering
term Item Standard value Usage limit Remarks
Tighten the rack guide spring Tighten with specified torque

45 Sakai put back
cap ( ° )
Manual steering gear Ay
1.5 s.o.5 {15 s.5} without boots
Ble load (N m {kg cm})
1.6 shi o. 5 {16 shi 5} With boots
SKI HIIO
tires
term Item Standard value Usage limit Remarks
Ku Ya rhinoceros
1.9 front wheel
145/95R10 Air pressure (Jcg/ai)
79/77L LT twenty two Rear wheel
evening stomach Ya Groove depth (Day 1) 1.6 or higher

SKIHI II
brake pedal
term eye Standard value Usage limit Summary
Beauty (1111) 0.5~6.0111D No vacuum on bus
Clearance mounting height ( nn) 143 5

From the center of the top surface of the pedal pad
105 DIDs or more
Foot rest (JIID) up to the floor panel
(When pedaling force is 30 kg, engine is running)
SKIHll2
front brake
term Item Standard value Usage limit I Remarks
Shoe thickness ( 11D) Drum Five 1
drum brake
I1
inner diameter (1) 180 181

SKIHll 3
rear brake
term Item Reference value Limit of use Remarks
Si Yu Thickness ( DD) Four 1
drum brake I1
Drum inner diameter (DID) 180 181
SKIHll4
parking brake
term Item Standard value Use limit Remarks
brake lever Pull out (notch) 3~5 operating force 20
SKIH115
H-4
[Engine Questionnaire Sheet ]
Question diagnosis Si Bok
Customer name Vehicle model Engine ÿ NIA, TIC, Mission ÿ 4M/T, 5M/T,
S/C, cab, 2WD, 4WD 2A/T, 3A/T,
looks
EFI, LPG 4A/T
frame no. Registration date km

Failure date I Mileage
car
Both equipment:
Ming
Customer (Driver) [Gender] [Age] ÿProfessionÿ [Main area of use] [Parking area]
woman Talent: City / Suburb / Coast / Mountain / Others Outdoor / Indoor
• No initial explosion • There is an initial detonation, but no complete detonation.
Poor starting. Hard to start (cold, warm, all the time)
• others ( )
•First idle effect • Low idling speed
disease
Abnormal idling •High idling speed • Unstable idling (at cold, warm, all the time)
• others ( )
. Breathing (when starting, accelerating, decelerating, fixed time) • Knocking
Poor drivability/backfire • Insufficient output • Poor acceleration • Poor blowing

letter
• others ( )
• When idling (during warm-up, after warm-up) • When starting • When driving ( )
engineering / station • Immediately after stopping (restartable, not restartable) • When under load (air conditioner electric load power steering)
• others ( )
Occurrence start time • From new car • Recently (since around month/year)
Occurrence frequency • Always • under certain conditions ( ) · Sometimes
• anytime
Weather conditions Weather/clear · cloudy . rain . war two • others ( )
Temperature •Temperature (about OC) (Spring/Summer/Autumn/Winter)
Engine / engine status. when it's cold . After warming up . Warming up (water temperature approx. OC)
road Road/City • Suburbs • highway • Mountain trails (up and down)
• irrelevant • No-load racing
Operating conditions •While driving (vehicle speed: km/h, engine rpm: rpm, MIT speed)
• Driving on a curve (right curve left curve )
Other circumstances
State of engine check lamp I • Always on • Occasionally lights up • Does not light up
I normal during inspection • Error code (

Diagnosis display (T terminal short circuit)
2nd I. Normal • Error code (
M E138
[Transmission Questionnaire Sheet ]
Question diagnosis Si Bok
Customer name vehicle type Engine ÿ NIA, TIC, Mission ÿ 4M/T, 5M/T,
S/C, cap. 2WD, 4WD 2A/T, 3A/T,
looks EFI, LPG 4A/T
frame no. Registration date km

Date of failure Distance traveled
car
Both equipment: Tires (bias , radial , snow , spikes, etc.) ) ] : Wheel [ Steel/Aluminum]
Ming
Customer (Driver) [Gender] [Age] ÿProfessionÿ [District of use] [Parking area]
woman talent Urban/suburb/coastal/mountainous/ other outdoor/indoor
present elephant Specific content
• Do not advance
Impossible to run/Do not go backwards
• Engine starting failure
• Clutch slips
Abnormal driving
disease
•Omi]•The car moves in the range
- Does not shift

Poor gear shifting
•The shift point shifts.
•The shift shock is large.

letter
Shift shock
•Long time lag when shifting gears
time lag
• The engine blows up when shifting gears
others
Occurrence start time • From new car •Recently (from around
Occurrence frequency • Always • under certain conditions ( ) •Sometimes
• anytime
Weather conditions Weather / sunny . cloudy . rain · snow • others ÿ ]
Temperature / Temperature (approx . °C ) [Spring/Anti/Autumn/Winter]
road street / city • Suburbs · highway •Mountain trail (climbing) , down)
• irrelevant •While driving
. at startup • Vehicle speed
Operating conditions
[
•Engine rotation km/h l rpm
• At the time of idling
• While driving on a curve ( • right curve•left curve)
Other circumstances
During inspection I •Normal • Error code [

Diagnosis display (T terminal short circuit)
2nd time 1 •Normal • Error code ÿ

Daihatsu Midget II SM 1996 Jpen

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Daihatsu Midget II SM 1996 Jpen

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capital fee Name Document code Publication date

Midget 1I Service Manual Commentary No. 1 EKOllA March 1996 _

wa ' !.()\' Li Industry Co., Ltd. Domestic Service Department

1111 table of contents 1111

maintenance section••••••••••••••••-------• Mouth ÿ Mouth 2 3- 1 Timing belt removal and installation

Grasping point ----------------------------------- ÿÿ [No] 4 3- 3 PREPARATION ---- PREPARATION ---

ÿSaioÿ 6 Jack P•1…………………… Mouth and ÿ] 4. Lubricating device —------------ ---------------------- ÿÿ

--- [Masao] | c. engine test _______________ _______________ 5 Cooling

inspection and adjustment ------------------------------------ [ Removal and installation ]

1111 table of contents 1111

_........ ......_.................. 1 0-2 system diagram•-••------ -----------------------....-------------- 4-1 Rear differential

—------------------- 3:00pm] 11 -1Preparation / Mingo

removal and installation . --

.................. ÿ •ÿÿ . . . . . . . . . . . . . . .....ÿ•Lyricsÿ 1 -1 Engine mounting removal, removal

-------------------------------------------------- 1 -4 Clutch Removal and installation of the riser bar …Masahiro]

transmission -------- ÿE[ Mounting ----------------------------------

ÿ 1111 table of contents 1111ÿ

Remove and install. . . . . . . . . . . . . . . . . . . . . . . . . . . . --Kazuro installation 5 Bumper- &

Add. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swallow each other]

4-10Remove and remove the parking brake

Speech ] Nation Nation Yo 1 building adjustment •----..-- _........_..---

[Giant King] 1- 1 Around the front panel•ÿÿ••••ÿ••••ÿ•ÿ•[Large i] One lamp

1111 table of contents 1111

1-1 engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [Watou]

1-2 drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ÿ E Engineering]

1-3 chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . {Watari yo}

How to read maintenance

1 How to read maintenance

1-1-2 Removal and installation (disassembly and assembly) procedures

How to read maintenance

1-1-3 Content omitted in this document

2. Clean and wash detached parts as required

1-1-4 Definition of terms

Example: 33.25 ft 13.25 N m {340 ft 135 kg cm}

1. New units due to the introduction of SI units

M (Mega) 106 d (deci) 10-1=0.1

k (Kilo) h 103 c 10-2=0.01

(Hect) 102 (centimeter) 10-3=0.001

da (deca) 101 m (millimeter) µ (micro) 10-6=0. 000001

3-1-2 How to grasp the tightening torque of nuts

Identification of strength class by actual product Identification by part number

Type Head shape (How to read the strength classification)

Nominal diameter around

Meaning of symbols and abbreviations used

4 Meaning of Symbols Used

symbol original language intention taste

RH Right Hand _ right side

RR Rear (rear) rear

Stringer Top Dead

Before Top Dead Center

EX Exhaust Represents the exhaust system.

American Petroleum Institute standards (abbreviated as

Special Service Tool

T Torque _ tightening torque

Combine two or more single parts or sub-assembly parts to form an assembly.

WI With (With) It comes with the following: (Example w/washer...with washer)

5 Precautions for general

Parts to be reused shall be inspected and measured in detail as necessary.

0 Jack-up support point

Rear side…Rear differential

Lift Support Points and Rigid Rack Support Points

7 Lift Support Points and Rigid Rack Support Points

--- [Masao] | c. engine test _ _ 5 Cooling