Vehicle Segment:
Compact Kei car / Utility Vehicle.
Target Audience:
Enthusiasts, restoration projects, owners requiring detailed maintenance and repair information.
Key Competitors Era:
Daihatsu Fellow Max, Subaru Rex, Honda Life (all within the Kei car segment).
Vehicle Attributes:
Compact size, fuel efficiency, 4WD capability (common in many variants), robust and simple mechanicals.
Manual Value Proposition:
Provides essential technical data and repair procedures crucial for maintaining these classic vehicles.
General Coverage:
Comprehensive repair and service procedures for the specified Suzuki Hatch models.
Specific Systems Covered:
Engine, Drivetrain (Transmission, Differentials), Suspension, Steering, Brakes, Fuel System, Electrical System (Ignition, Lighting, Accessories), Cooling System, Lubrication System, Bodywork, Chassis.
Estimated Page Count:
300-500 (typical for a comprehensive service manual of this era)
Type:
Service and Repair Manual
Engine Mechanical:
Engine assembly, disassembly, overhaul, piston rings, bearings, cylinder head, crankshaft, camshaft, valve train.
Engine Management:
Carburetor systems, ignition timing, spark plug specifications, fuel pump operation.
Transmission Manual:
Gearbox overhaul, clutch service, shift linkage adjustment.
Drivetrain 4Wd:
Transfer case operation and service, front and rear axle components, driveshafts.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications.
Steering:
Steering column, tie rods, steering linkage, steering gear (if applicable).
Brakes:
Drum and disc brake systems (depending on model variant), brake fluid specifications, bleeding procedures, master cylinder and wheel cylinder service.
Electrical System:
Wiring diagrams, lighting circuits, starter motor, alternator, battery specifications, fuse box layout, accessory circuits.
Cooling System:
Radiator, water pump, thermostat, coolant specifications, fan operation.
Lubrication System:
Oil pump, oil filter specifications, oil change intervals, lubrication points.
Fuel System:
Fuel tank, fuel lines, carburetor (model dependent), fuel filter replacement.
Body And Chassis:
Body panel removal/installation, door mechanisms, interior trim, chassis lubrication points.
Maintenance Routine:
Scheduled maintenance tasks, fluid level checks, filter replacements, belt adjustments.
Troubleshooting Diagnostics:
Diagnostic charts for common symptoms, identification of potential causes, basic electrical testing.
Repair Overhaul:
Detailed step-by-step instructions for component removal, repair, and reassembly.
Adjustment Calibration:
Carburetor adjustments, ignition timing settings, clutch and brake adjustments.
Special Tools Usage:
Identification and usage of specialized tools required for specific repair procedures.
Depth:
Comprehensive: Covers from basic maintenance to major overhauls and diagnostics.
Diagnostic Focus:
Emphasis on practical diagnostics for on-road issues and common failures.
Specification Detail:
Includes critical torque specifications, clearances, and tolerances for engine and drivetrain components.
Searchability:
Text-searchable (OCR processed for efficient information retrieval).
Printability:
Printable pages for easy reference in a workshop environment.
Image Resolution:
High-resolution images and diagrams suitable for clear visual guidance.
Digital Binding:
N/A (Digital format, bookmarking and table of contents available).
Digital Paper Simulation:
N/A (Digital format, but original manual would have been printed on durable paper for workshop use).
Engine Type:
Inline 3-cylinder, naturally aspirated
Bore X Stroke:
64.0 mm x 56.0 mm (typical for F5A)
Compression Ratio:
8.4:1 (typical)
Horsepower Ps:
27-30 PS @ 5500-6000 RPM (approximate, varies by tuning and year)
Torque Nm:
3.9-4.2 kgf·m (approx. 38-41 Nm) @ 3000-3500 RPM (approximate)
Carburetor Type:
Single-barrel downdraft carburetor (e.g., Hitachi or Mikuni variants)
Fuel Type:
Unleaded gasoline (Octane rating may be lower, consult original specs)
Ignition Type:
Conventional distributor ignition system
Cooling Method:
Water-cooled
Oil Capacity Liters:
2.5 L (approximate, including filter)
Length Mm:
3,195 mm (typical Kei car regulations)
Width Mm:
1,395 mm (typical Kei car regulations)
Height Mm:
1,350-1,500 mm (varies with body style, e.g., van/truck variants)
Curb Weight Kg:
550-650 kg (approximate, depending on configuration)
Gross Vehicle Weight Rating Kg:
900-1000 kg (approximate)
Wheelbase:
2,045 mm (typical)
Front Track:
1,200 mm (approximate)
Rear Track:
1,210 mm (approximate)
Oil Change Km:
5,000-7,500 km or 6 months (typical recommendation)
Air Filter Replacement Km:
15,000-20,000 km or annually
Spark Plug Replacement Km:
20,000-30,000 km (depending on plug type)
Engine Oil Type:
API SF/CD 10W-30 or 10W-40 (Consult manual for precise viscosity and API rating)
Coolant Type:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Engine Wear:
Potential for piston ring wear and oil consumption due to age and mileage; gasket leaks (head gasket, valve cover).
Carburetor Issues:
Carburetor gumming, idle instability, wear on throttle shafts.
Electrical Corrosion:
Corrosion in wiring harnesses, connectors, and grounds due to age and exposure.
Rust Corrosion:
Susceptibility to rust, particularly on the chassis, underbody, and body panels, especially in regions with road salt.
Suzuki Automotive:
Suzuki's long history in producing small, reliable vehicles, particularly Kei cars for the Japanese domestic market.
Hatch Lineage:
Part of Suzuki's early utility vehicle and Kei car offerings, predating models like the Alto and Jimny in their later iterations, but sharing a spirit of practicality and compact design.
Manufacturing Location:
Japan
Production Period Context:
Developed during Japan's economic growth period, emphasizing efficient and affordable personal transportation.
