SUZUKI LJ50 LJ50V 4WD JIMNY & VAN FACTORY Workshop Manual

T o: Technical personnel of every SUZUKI servi ce shop This SERVICE MANUAL prov ides all information necessary for servicing the SUZUKI four- wheel vehicle with a tarp top, Model LJ50, and its panel-van version, Model LJ50V . The vehicle is viewed as composed of three divisions-engine, chassis and electrical equipment-from the standpoint of servicing and maintenance. Each is described, and for each are set forth the checking, inspecting and overhauling instructions, together with pertinent advices and sugges- tions designed to improve the efficiency of servicing wor k. The engine for powering these models, LJ50 and LJ50V, is a three-cylinder, water-cooled, two- st roke-cycle unit equipped with an intake reed valve for developing greater low-speed torque. It is built to include those basic design features that have earned high prestige for SUZUKI en- gines. Durable and sturdy, it is capable of high performance whether the car is used as an on- the-road or an oH-the-road vehicle. For enabling each user to derive maximum benefit from his LJ50 or LJ50V car, we as manufac- turer heavily depend on you-the person who directly comes into contact with the user and looks after his car from time to time-as a vital link between us and users. With this notion as the premise, this MANUAL has been prepared. It is hoped that you will find this MAN UAL easy to read and consult for your work on the LJ50 and LJ 50V cars. Models LJ50 and LJ50V may undergo some design changes in the future. If you find some of the contents of this MANUAL being at variance with the car in your care, it is because the changes have been effected. In such a case, please do not hesitate to enquire us. Each change is covered in our technical bulletin; you will be referred to the bulletins or will receive information directly from us. July, 1974. SUZUKI MOTOR COMPANY, LIMI TE D International Service Dep artment - 1 -

GENERAL SPECIAL T OOLS AND SERVICE MATERIALS ENGINE CARBURETOR AIR CLEAN F UEL PUMP AND FILTER ENGINE COOLING SYSTEM CAR HEATER IGNIT I ON SYSTEM STARTER MOTOR CHARGING SYSTEM CLUTCH GEAR SHiniNG CONTROL TRANSM I SSION TRANSFER GEAR BOX PRO PEL LER SHAFTS DI FFE RENTIAL SUSPENSION STEER I NG SYSTEM BRAKES DOOR AND TARP TOP BODY ELECTRICAL IPMENT M AINTENANCE SCHEDULES 3

1. GENERAL 1- 1. Exterior View . ..... ... .. .. .. .... ... . .... . . . . . . . . . . . . . . . .. 6 1- 2. Dimensions ............. ...... ... ........................ 7 1- 3. Specifications ..................... ................. ..... . 9 1- 4. General Rules on Servicing Work ................ . ...... .. ..... 13 • - 5 -

i-I. Exterior View 1. LJ50 Fig . 1-1 2. LJ50V Fig . 1-2 - 6 -

1-2. Dimensions 1. LJ50 I \ \ I I I 1 1 I --1 _I ----7 /' I : 1 I I , ____ J 1 / / 1 I I 1 I 1-- L_ f----OLS- OIL 1-- -------- -° 1 '" i --- - - -- OLLt '---OSL -- Fig. 1-3 - 7 -

2. LJ50V 1 , I I , ...... - - - _/ \- -- - -- - 0991 - - - --- ---< -- - 0911 - - - --1 / \ 1 ,, - -- / I I...... _ / I - 7----="---":"', - - - +-.... :-=-=", ,'- I - - -- - \ ', (- I - -- - - \ \ '" C> M '" I I I I ,--" n -=- It l =§" - \ --, '---.) - -s zs- I ;If I-+-- 1 f8r-- I lrlt;i r'I V Ql rr kn IfQ n ffI +----= i ----.' C> - f---- SIL Overall Overall Overall Weight Weight Fig. 1-4 - 8 -

1-3. Specifications ______________ Models LJ50 LJ50V I tern ______________ Dimension Ov erall length Overall width Overall heigh t Wheel base Ground clearance Cargo deck space L x W x H Weight Weight Seating ca pacity Maximum pay load Weigh t distribu tion , front re ar Curb weight Performance Climbing a bility Turning radius Braking distance Engine Type Number of cylinder Bore x Stroke Piston displ a cement Compr ession ra tio Compression pressu re Maximum horse power Maximum torque Weight Dimensions LxW x H Numb er of piston ring Inlet system Exhaust system Starting system I • Cooling System Type Radiator 3,180 mm (125.2 in.) 1, 295mm( 51. 0 in.) 1,710 mm ( 67.3 in.) 1,930 mm ( 76.0 in.) 240 mm ( 9.4 in.) 930 x 1 ,205 x 1,040 mm (36. 61 x 4 7.44 x 40.94 in.) 700 kg (1 , 54 3 lb) 2 persons 250 kg ( 5501b) 43 5kg( 9571b) 625 kg (1,375 lb) 1,060 kg (2,3 32 lb) 36.5 ° (tan e 0. 74) 4.6 m (15 .1 ft) 14 m (45 .9 ft) at 50 kph (31 mph) 3,025 mm (119.1 in.) 1,295 mm ( 51.0 in .) 1,660 mm ( 65.4 in.) 1,930 mm ( 76.0 in.) 210 mm ( 8.3 in.) 820 x 1,165 x 1,045 mm (32.28 x 45. 86 x 41.14 in.) 730 kg (1,609 lb) 2 persons 200kg( 4401b) 440kg( 9681b) 600 kg (1,320 lb) 1,040 kg (2 , 288 lb) 34.3 ° (tan e 0.68) 4.6 m (15.1 ft) 14 m (45.9 ft) at 50 kph (31 mph) 2-stroke , water cooled Three 6l.0 x 61.5 mm (2.40 x 2.42 in.) 539 cc 6.0 7 kg/cm 2 (99.5 psi) at 1,000 rpm 33 Hp at 5,500 rpm 5 .85 kg-m (41.6 lb-ft) at 3,500 rpm 66 kg (1 45 lb) 490 x 5 88 x 500 mm (19.29 x 23.15 x 19 . 69 in .) Three Reed valve Piston valve Star t er mtor Water cooled di.rect Corrugated fin and tube pr e ssure 2-stroke , water cooled Three 61.0 x 61.5 mm (2.40 x 2.42 in.) 539 cc 6.0 7 kg/ cm 2 (99.5 psi) at 1,000 rpm 33 Hp at 5,500 rpm 5.85 kg-m (41.6 lb-ft) at 3,500 rpm 66 kg (145 lb) 490 x 5 88 x 500 mm (19.29 x 23 . 15 x 19.69 in . ) Three Re ed valve Piston valve Starter motor Water cooled direct Corrugated [in and tube pressure - 9 -

II Item LJ50 LJ50Y Cooling System Water pump Centrifugal type, Centrifugal type, V-belt drive V-belt drive Thermostat Wax pellet element type Wax pellet element type Cooling solution capacity radiator 3.51tr 3 5 Itr (7.40/6.21 US/Imp. pt) (7.40/6.21 US/Imp . pt) Reserve tank 0.61tr 0.6 ltr (1.27/1.07 US/Imp . pt) (1.27/1.07 US/Imp. pt) Ignition System Ignition timing 8° B.T .D.C . below 8° B.T.D.C. below 1,000 rpm. 1,000 rpm. Spark plug NGK B-7HS, NGK B-7HS, NIPPON DENSO W22FS NIPPON DENSO W22FS Spark plug thread size DxL 14 x 12.7 mm 14 x 12.7 mm (0.55 x 0.50 in.) (0.55 x 0.50 in .) Spark plug gap 0.7 mm (0 . 028 in.) 0.7 mm (0 .028 in.) Distribu tor point gap 0.4 mm (0.016 in.) 0.4 mm (0. 016 in.) Condenser capacity 0. 15 pF 0.15 pF Fuel System Number & type of carburetor Single, YCI 30-25 Single, YCI 30-25 Venture diameter 25 mm (0.98 in.) 25 mm (0.98 in.) Air cleaner Wet polyurethane type Wet polyurethane type Fuel pump Diaphragm type Diaphragm type Fuel tank capacity 30ltr 30ltr (7.93/6.60 US/Imp. gal) (7.93/6 .60 US/Imp. gal) Lubrication System Engine lubrication CCI lubrication CCI lubrication Oil pump Plunger type Plunger type Engine oil tank capacity 3.4 Itr 3.4 ltr (7.18/6.04 US/Imp. pt) (7.18/6.04 US/Imp. pt) Transmission oil 1,000 cc 1,000 cc (2.12/1.76 US/Imp. pt) (2.12/l.76 US/ Imp. pt) Differential gear box oil 1,300 cc 1,3 00 cc (2.75/2.31 US/Imp . pt) (2.75/2.31 US/Imp. pt) Transfer gear box oil 900 cc 900 cc (1.90/1.60 US/Imp. pt) (1.90/1.60 US/Imp. pt) Electrical System Battery NS 40Z NS 40Z Battery capacity & voltage 35 AH, 12 Y 35 AH, 12 Y Starter Magnetic shift, 0.6 KW Magnetic shift, 0.6 KW Generator Alternator, 12 Y-35 A Alternator, 12 Y-35 A Head lamp 12 Y, 50/40 W 12 Y, 50/40 W Turn signal lamp 12Y,23W 12Y,23W EI P. 'fa Sli B; Pc F\ Tl Tr Gt Gt 'D Tr a. Cl 0, d1 Fr OJ Tj F Ji U. W Ti Ti; WI Sh Su St St St .- 10 -

I Item LJ50 LJ50V Electrical System Parking lamp 12V,3.4W 12 V, 3.4 W Tail/brake lamp 12 V. 8/23 W 12 V, 8/23 W Side turn signal lamp 12 V, 6 W 12 V, 6 W License plate lamp 12V,10W 12 V, lOW Back up lamp 12 V, 10 W 12 V, 10 W Positioning lamp 12 V, 8 W 12 V, 8 W Main fuse 30 A 30 A Fuse box 10 A, 10 A, 15 A 10 A, 10 A, 15 A Transmission Transmission gear 4-speed forward, all 4-speed forward, all synchromesh, 1 reverse synchromesh, 1 reverse Gear shift control Floor Floor Gear ratio, low 3.835 (30/14 x 34/19) 3.835 (30/14 x 34/19) 2nd 2.359 (29/22 x 34/19) 2.359 (29/22 x 34/19) I 3rd 1.524 (23/27 x 34/19) 1.524 (23/27 x 34/19) I top 1.000 1.000 reverse 4.026 (27/12 x 34/19) 4.026 (27/12 x 34/19) Transfer Transfer gear 2-speed with constantmesh 2-speed with constantmesh Gear ratio, low range 3.012 (32/22 x 29/14) 2. 571 (32/21 x 27/16) high range 1. 714 (24/29 x 29/14) 1.563 (25/27 x 27/16) Clutch Clutch Dry, single disc Dry, single disc Clu tch facing size O.D. x LD. 180 x 124 mm 180 x 124 mm I (7.08 x 4.88 in.) (7. 08 x 4.88 in.) I Friction area 134 sq . cm (20.7 sq. in.) 134 sq . cm (20.7 sq. in.) Differen tial Type Spiral bevel gear Spiral bevel gear Final ratio 4.875 (39/8) 4. 875 (39/8) Universal joint Cross joint Cross joint Wheel and Suspension Tire size 6.00 - 16 in., 4PR 5.60 - 15 in., 4PR Tire pressure, front 1.2 sq . cm (17 sq. in.) 1.2 sq. cm (17 sq. in.) rear 1.8 sq. cm (26 sq. in.) 1.8 sq. cm (26 sq. in.) Wheel rim size 4.50 E x 16 4.50 E x 15 Shock absorber, front and rear Telescopic, double action Telescopic, double action Suspension, front and rear Semi-elliptic, leaf spring Semi-elliptic, leaf spring Steering System Steering gear box Ball screw nut Ball screw nut Steering ratio 15.58 15.58 I

SUZUKI LJ50 LJ50V 4WD JIMNY & VAN FACTORY Workshop Manual

You're Reading a Preview

Recently Viewed