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MARUTI SUZUKI 800, Owner'S Manual

The Yamaha 800 Owner's Manual is a comprehensive guide to operating and maintaining your Yamaha 800. With detailed instructions and illustrations, this manual is essential for maximizing the performance and longevity of your vehicle. Download it for free from manualshive.com and unleash the full potential of your Yamaha 800.

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71

MARUTI 800 DOMESTIC

844-74E

INSPECTION AND MAINTENANCE

9-4

Interval: This interval should be judged

FREE INSPECTIONS

PERIODIC MAINTENANCE SERVICE AT COST

by odometer reading or months,

km

 (x 1,000)

1

5

10

20

30

40

50

60

70

80

whichever comes first.

months

1

6

12

24

36

48

60

72

84

96

WHEEL

1. Tyres (air pressure, abnormal wear, crack, ROTATION)

I

I&O

I&O

I&O

I&O

I&O

I&O

I&O

I&O

I&O

2. Wheels (damage)

I

I

I

I

I

I

I

I

I

I

3. Front wheel bearings (loose, damage)

–

I

I

I

I

I

I

I

I

I

4. Rear wheel bearings (loose, damage)

–

I

I

I

I

I

I

I

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FRONT AND REAR SUSPENSION

1. Suspension strut (oil leakage, damage)

I

I

I

I

I

I

I

I

I

I

2. Suspension arms and knuckle supports (loose,damage)

–

I

I

I

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I

I

I

I

I

3. Rear spring (damage)

–

I

I

I

I

I

I

I

I

I

4. Shock absorbers (oil leakage, damage)

I

I

I

I

I

I

I

I

I

I

5. All bolts and nuts (loose)

–

T

T

T

T

T

T

T

T

T

6. Suspension arms and Tension rods

–

I

I

I

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I

I

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STEERING

1. Steering wheel (play, loose)

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2. All rods and arms (loose, damage, wear)

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I

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ELECTRICAL

1. Battery electrolyte (level, leakage)

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I

I

I

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I

I

2. Wiring harness connection (looseness, damage)

–

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I

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I

3. Lighting system (operation, stains, damage)

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I

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4. Horn (operation)

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5. System voltage

–

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BODY

1. All chassis bolts and nuts (tighten)

–

I

T

T

T

T

T

T

T

T

2. All Latches, Hinges & Locks (function)

I

I&L

I&L

I&L

I&L

I&L

I&L

I&L

I&L

I&L

Summary of Contents for 800

Page 1: ...BEFORE DRIVING 4 STEERING COLUME CONTROLS 5 INSTRUMENT PANEL 6 OTHER CONTROLS AND EQUIPMENT 7 OPERATING YOUR VEHICLE 8 DRIVING TIPS AND SAFE DRIVING 9 INSPECTION AND MAINTENANCE 10 EMERGENCY SERVICE 11 BODY WORK CARE 12 GENERAL INFORMATION 13 FOR LPG KIT FITTED VEHICLE 14 SPECIFICATION ...

Page 2: ...2 59K 76G 844 74E ...

Page 3: ...t product information available at the time of publication Due to improvements or other changes there may be discrepancies between information in this manual and your vehicle MARUTI SUZUKI reserves the right to make changes at any time without notice This vehicle may not comply with standards or regulations of other countries Before attempting to register this vehicle in any other country check al...

Page 4: ... the body which absorbs larger part of impact energy in the event of a front collision and protects the occupants from impact Do not use any fitments such as crash guards These fitments will increase the risk to the occupants because of the shock directly getting transmitted to the occupants CAUTION Improper instllation of moble communication euipment such as cellular talephones or CB Citizen s Ba...

Page 5: ... Service Department The Addresses and Phone nos are given in Service Network booklet provided along with vehicle MODEL CHASSIS NO ENGINE NO DATE OF MILEAGE BATTERY DELIVERY MAKE SR NO BATCH CODE km OWNER S NAME ADDRESS ____________________________________________________________________________ _____________________________________________________________________ TEL NO _________________________ A...

Page 6: ...4 74E F free Service P Paid Service W Warranty A Accident MAINTENANCE SERVICE RECORD DATE OF KIND OF MILEAGE DESCRIPTION OF JOB NAME OF SERVICING JOB CARD MECHANIC S SERVICE SERVICE km DEALER MASS NO SIGNATURE 1 2 ...

Page 7: ... of manufacture The owner is responsible for any repair or replacements which are not covered by this warranty 4 Limitation This warranty shall not apply to a normal maintenance service required other than the three free services including without limitation oil and fluid changes headlight aiming fastener retightening wheel balancing wheel alignment and tyre rotation cleaning of injectors adjustme...

Page 8: ...n that the warranty registration PDI card was completed at the time of delivery of the vehicle b have performed at his own expenses by an Maruti Suzuki authorised dealer service station all the service inspections specified in the Maruti Suzuki Owner s Manual and Service Booklet and maintain adequate proof that such service inspections have been performed c make certain that the Maruti Suzuki auth...

Page 9: ...Annexure A has a manufacturing defect c Vehicle is unable to meet the Emission Standards as given in 1 inspite of the vehicle having been maintained and used in accordance with the instructions as specified in Owner s Manual and Service Booklet and the used fuel and different oils Engine oil Transmission oil Brake oil etc are also as per specification 3 The method of examination for deciding the w...

Page 10: ...tions as specified in the Owner s Manual and Service Booklet need to be followed and recorded in the manual for emission warranty 11 The customer needs to produce the PUC Pollution Under Control certificate valid for the period preceding the test during which the failure is discovered The receipts for the maintenance of the vehicle as per specification in Owner s Manual and Service Booklet from th...

Page 11: ... Control Module ECM 3 Intake Manifold 4 EGR valve 5 Distributor and internal parts 6 Ignitions coil 7 Canister Assembly 8 Vapour Liquid Separator 9 Fuel Tank and Filler Cap 10 PCV Positive Crankcase Ventilation Valve 11 Oil Filler Cap 12 Catalytic Convertor 13 Exhaust manifold 14 All fuel injection System related SENSORS 15 Maniverter EMISSION WARRANTY 2 5 ...

Page 12: ...12 59K 76G 844 74E EMISSION WARRANTY ...

Page 13: ...44 74E 3 BEFORE DRIVING BEFORE DRIVING Fuel Recommendation 3 1 Keys 3 2 Immobilizer Key if equipped 3 2 Door Locks 3 3 Windows 3 4 Mirrors 3 4 Front Seat Adjustment 3 5 Adjustable Head Restraints if equipped 3 6 Seat Belts 3 6 ...

Page 14: ...ilable in some areas DO NOT USE fuels containing more than 5 methanol under any circumstances Fuel system damage or vehicle performance problems resulting from the use of such fuels are not the responsibility of MARUTI SUZUKI and may not be covered under Warranty Fuels containing 5 or less methanol may be suitable for use in your vehicle if they contain cosolvents and corrosion inhibitors NOTE If ...

Page 15: ... the tag in a safe place If you lose your keys you will need this number to have new keys made Write the number down and keep it in a safe accessible place away from the vehicle KEYS w w w w w WARNING Do not use locally made key Should you require a duplicate key place your order with a MARUTI SUZUKI dealer only Note Keep the spare key very carefully When it is lost consult your dealer by quoting ...

Page 16: ...he immobilizer key it may not start the engine The immobilizer key is a sensitive electronic instrument To avoid damaging the immobilizer key Do not expose it to impacts moisture or high temperature such as by leaving it on the dashboard under direct sunlight Keep the immobilizer key away from magnetic objects This system is designed to help prevent vehicle theft by electronically disabling the en...

Page 17: ... the key to lift up the lid or the key may break off in the lock CAUTION Hatchback To unlock insert the key fully in to the lock knob and turn it anticlockwise and to lock turn it clockwise Hatchback can be opened by pushing in the lock knob and lifting hook shaped grip Always make sure that the hatchback is closed and latched securely Completely closing it helps keep exhaust gases from entering t...

Page 18: ...or up down or sideways to obtain the best view Outside Rearview Mirror Adjust the outside rearview mirror so you can just see the side of your vehicle in the mirror Be careful when judging the size or distance of a vehicle or other object seen in the side convex mirror if equipped Be aware that objects look smaller and appear farther away than when seen in a flat mirror w w w w w WARNING 844 03 00...

Page 19: ...ry to move the seat forward and rearward to ensure that it is securely latched To avoid excessive seat belt slack which reduces the effectiveness of the seat belts as a safety device make sure that the seats are adjusted before the seat belts are fastened Adjusting Seatbacks The seatbacks can be adjusted to different angles To adjust the seatback angle pull up the lever on the outboard side of the...

Page 20: ... for the head restraints To raise the head restraint pull upward on the restraint until it clicks To lower the restraint push down on the restraint while holding in the lock lever If a head restraint must be removed for cleaning replacement etc push in the lock lever and pull the head restraint all the way out Wear Your Seat Belts at All Times There are two types of seat belt Automatic retracting ...

Page 21: ...elt press the release button on the buckle catch To Adjust the Belt Automatic retracting type Pull the shoulder portion of the belt upwards through the tongue plate The length of the diagonal shoulder strap adjusts itself to allow freedom of movement The seat belt has an emergency locking retractor ELR which is designed to lock the seat belt only during a sudden stop or impact No modifications or ...

Page 22: ...lt ineffective in accidents The shoulder portion should be worn on the outside shoulder only and never under the arm Inspect all seat belts after any collision Any automatic retracting type belt which was in use at the time of collision and subjected to stress must be replaced Any automatic retracting type belt not in use at the time of collision should be carefully inspected and the static operat...

Page 23: ...at belt over an infant or child being held on an occupant s lap Such seat belt use could cause serious injury in the event of an accident Pregnant women should use seat belts although specific recommen dations about restraint use should be made by the woman s medical advisor Periodically inspect seat belt assemblies for excessive wear and damage Seat belts should be replaced if webbing becomes fra...

Page 24: ...24 844 74E MEMO ...

Page 25: ...UTI 800 DOMESTIC 844 74E 4 STEERING COLUMN CONTROLS STEERING COLUMN CONTROLS Ignition Switch 4 1 Lighting Turn Signal Control Lever 4 2 Hazard Warning Switch 4 3 Windscreen Wiper and Washer Lever 4 4 Horn 4 5 ...

Page 26: ... can be removed The LOCK position locks the ignition and prevents normal use of the steering wheel after the key is removed To release the steering lock fully insert the key and turn it clockwise to one of the other positions If you have trouble turning the key to unlock the steering try turning the steering wheel slightly to the right or left while turning the key To avoid possible injury do not ...

Page 27: ...e engine starts Never remove the ignition key while the vehicle is moving The steering wheel will lock and you will not be able to steer the vehicle Do not leave children alone in a parked vehicle Unattended children could cause accidental movement of the vehicle which could result in severe personal injury Always remove the key when parked to prevent unintentional operation of the vehicle and to ...

Page 28: ...tch in the ON position move the lever clockwise until it clicks to signal a right turn or anticlockwise to signal a left turn When the turn is completed the signal will cancel and the lever will return to its normal position HAZARD WARNING SWITCH Pull up the hazard warning switch to activate the hazard warning lights All four turn signal lights and both turn signal indicators will flash simultaneo...

Page 29: ...very convenient for driving in mist or light rain In the LOW position the wipers operate at a steady low speed In the HI position the wipers operate at a steady high speed To turn off the wipers move the lever back to the OFF position w w w w w WARNING To help prevent damage to the windscreen wiper and washer system components you should take the following precautions Do not continue to hold in th...

Page 30: ...30 MARUTI 800 DOMESTIC 844 74E STEERING COLUMN CONTROLS 4 5 HORN Press the horn button of the steering wheel to sound the horn The horn will sound with the ignition switch in any position 844 04 009 ...

Page 31: ...Lights 5 2 Immobilizer System Light if equipped 5 2 Speedometer Odometer 5 4 Fuel Gauge 5 4 Temperature Gauge 5 5 Ashtray if equipped 5 5 Glove Box 5 6 Head Light Leveling Switch if equipped 5 6 Heating System if equipped 5 7 System Operating Instructions 5 8 Air Conditioning System if equipped 5 11 System Operating Instructions 5 11 ...

Page 32: ...5 Hazard warning switch 6 Other switches if equipped 7 Heater control panel 8 Cigarette lighter if equipped 9 Ashtray if equipped 10 Bonnet release 11 Center ventilator 12 Side ventilator 13 Side defroster 14 Glove box 15 Fuse box INSTRUMENT PANEL 1 Speedometer 2 Odometer 3 Fuel Gauge 4 Temperature gauge 5 Warning and indicator lights INSTRUMENT CLUSTER 844 05 001 844 05 002 ...

Page 33: ... MARUTI SUZUKI dealer to inspect the brake system If the brake fluid level warning light does not go out after the engine has been started If the brake fluid level warning light does not come on when the ignition switch is turned to the ON position If the brake fluid level warning light comes on at any time during vehicle operation NOTE Because the disc brake system is self adjusting the fluid lev...

Page 34: ...th the charging light ON as this will drain the battery dead CAUTION Malfunction Indicator Light Your vehicle has a computer controlled emission control system A Malfunction Indicator light is provided on the instrument panel to indicate when it is necessary to have the emission control system serviced The Malfunction Indicator light comes on when the ignition switch is turned to ON and goes out w...

Page 35: ...speed in km h The odometer records the total distance the vehicle has been driven Keep track of your odometer reading and check the maintenance schedule regularly for required services Increased wear or damage to certain parts can result from failure to perform required services at the proper mileage intervals and your warranty rights may be affected CAUTION When the ignition switch is turned to t...

Page 36: ...he engine coolant temperature Under normal driving conditions the indicator should stay within the normal acceptable temperature range between H and C If the indicator exceeds this range and veers towards H overheating is indicated Follow the instructions for engine overheating in the EMERGENCY REMEDIES section Continuing to drive the vehicle when engine overheating is indicated can result in seve...

Page 37: ...ould create a fire hazard w w w w w WARNING GLOVE BOX To open the glove box pull the latch lever To close it push the lid until it latches securely Never drive with the glove box lid open It could cause injury if an accident occurs w w w w w WARNING Level the headlight beam according to the load condition of your vehicle by turning this switch The chart shows the appropriate switch position for di...

Page 38: ...MESTIC 844 74E INSTRUMENT PANEL 5 7 Vehicle load Switch Position Condition Driver only 0 Driver 1 passengers 0 in front seat Driver 3 passengers 1 No cargo Driver 3 passengers 2 Cargo added Driver full cargo 3 Dummy 4 ...

Page 39: ...844 74E INSTRUMENT PANEL 5 8 HEATING SYSTEM if equipped The heating system provides heating demisting and ventilation a Windscreen defroster b Side defroster c Side outlet d Center outlet e Floor outlet 844 05 018 844 05 019 ...

Page 40: ...floor outlets HEAT DEFROST 6 Temp erature controlled air comes out of the floor outlets the windscreen defroster outlets and the side defroster outlets DEFROST 7 Temperature controlled air comes out of the windscreen defroster outlets and the side defroster outlets Air Intake Lever 8 This lever is used to select between circulating outside air FRESH AIR or recirculating inside air RECIRCULATED AIR...

Page 41: ... the fan switch to the desired fan speed position Moving the fan switch to a higher fan speed position increases heating efficiency Quick Heating Using recirculated air The lever settings are the same as for normal heating except you move the air intake lever to RECIRCULATED AIR If you use this heating method for an extended period of time the air in the vehicle can become contaminated and the win...

Page 42: ...ROST HEAT the air intake lever to FRESH AIR the temperature control dial to the desired temperature position and the fan switch to HIGH When the windscreen has become clear move the fan switch to the desired fan speed position Cool Face Warm Feet Move the function selector to BI LEVEL the air intake lever to FRESH AIR the temperature control dial to the desired temperature position and the fan swi...

Page 43: ...em push the A C button again During operation of the air conditioner you may notice slight changes in engine speed These changes are normal the system is designed so that the compressor turns on or off to maintain the desired temperature Less operation of the compressor results in better fuel economy Normal Cooling using outside air push in the A C button move the function selector to VENTILATION ...

Page 44: ...function position the air intake lever to FRESH AIR the temperature control dial to the desired temperature position and the fan switch to the desired fan speed position NOTE Because the air conditioner dehumidifies the air turning it on will help keep the windows clear even when blowing heated air using the DEMIST or HEATER DEMIST functions NOTE There are two types of air conditioning systems use...

Page 45: ...MENT 6 OTHER CONTROLS AND EQUIPMENT Parking Brake Lever 6 1 Pedals 6 2 Gear Lever 6 2 Fuel Filler Cap 6 3 Folding Rear Seats 6 4 Sun Visor 6 5 Interior Light Switch 6 5 Assist Grips 6 5 Bonnet 6 6 Tyre Changing Tools 6 7 High Mount Stop Lamp if equipped 6 7 ...

Page 46: ...dal down and pull the parking brake lever all the way up To release the parking brake hold the brake pedal down pull up slightly on the parking brake lever push the button on the end of the lever with your thumb and lower the lever to its original position w w w w w WARNING w w w w w WARNING Never drive your vehicle with the parking brake on rear brake effectiveness can be reduced from over heatin...

Page 47: ...result in excessive clutch wear clutch damage or unexpected loss of engine braking Brake Pedal 2 2 2 2 2 Your MARUTI SUZUKI vehicle is equipped with front disc brakes and rear drum brakes Depressing the brake pedal applies both sets of brakes You may hear occasional brake squeal when you apply the brakes This is a normal condition caused by environmental factors such as cold wet snow etc If brake ...

Page 48: ...ARNING Petrol is extremely flammable Do not smoke when refuelling and make sure there are no open flames or sparks in the area w w w w w WARNING To remove turn the cap counterclock wise Turn the cap slowly to allow any residual pressure to escape To install turn the cap clockwise If you need to replace the fuel cap use only a cap specified for your model Using an improper fuel cap can cause a seri...

Page 49: ...seat of your vehicle can be folded forward to provide additional luggage space Luggage or other cargo should be stowed in the luggage compartment with the rear seat in an upright position whenever possible If you need to carry cargo in the passenger compartment with the rear seat back folded forward be sure to secure the cargo or it may be thrown about causing injury Never pile cargo higher than t...

Page 50: ...as three positions which function as described below 1 The light remains off even when the door is opened 2 The light comes on when the door is opened 3 The light comes on and stays on regardless of whether the door is open or closed NOTE Only front doors are involved in lighting operation of interior light CAUTION ASSIST GRIPS Assist grips are provided for passenger convenience Do not hang items ...

Page 51: ... 2 Push the under bonnet release lever upwards with your finger as shown in the illustration While pushing the lever lift up the bonnet 3 Continue to lift up the bonnet until it is high enough to support with the prop rod Make sure the bonnet is fully closed and latched before driving If it is not it can fly up unexpectedly during driving obstructing your view and resulting in an accident w w w w ...

Page 52: ...ENCY SERVICE section of this manual before attempting to use the jack After using the jack jack handle and wheel wrench be sure to stow them securely or they can cause injury if an accident occurs w w w w w WARNING w w w w w WARNING HIGH MOUNT STOP LAMP if equipped High mount stop lamp is provided with your vehicle and is fitted on back door The stop lamp will glow as when the brake pedal will be ...

Page 53: ... YOUR VEHICLE 7 OPERATING YOUR VEHICLE Exhaust Gas Warning 7 1 Daily Inspection Checklist 7 1 Starting the Engine 7 2 Using the Transmission 7 3 Braking 7 4 Running in 7 4 Catalytic Converter 7 5 Improving Fuel Economy 7 6 Trailer Towing 7 6 ...

Page 54: ...w w WARNING Before driving 1 Make sure that windows mirrors lights and reflectors are clean and unobstructed 2 Check the tyres 3 Look for fluid and oil leaks NOTE It is normal for water to drip from the air conditioning system after use 4 Adjust the seat head restraint 5 Check the brake pedal and the parking brake lever 6 Adjust the mirrors 7 Make sure that you and passengers have properly fastene...

Page 55: ...ranking wait about 15 seconds then press down the accelerator pedal to 1 3 of its travel and try cranking the engine again Release the key and accelerator pedal when the engine starts If the engine still does not start try holding the accelerator pedal all the way to the floor while cranking This should clear the engine if it is flooded Once a week or each time you fill your fuel tank perform the ...

Page 56: ...h Fourth 30 km h Top Speed Fifth 40 km h Top Speed Applicable for 5 speed transmission only Reduce your speed and change down to a lower gear before going down a long or steep hill A lower gear will allow the engine to provide braking Avoid riding the brakes or they may overheat resulting in brake failure When driving on slippery roads be sure to slow down before changing down Excessive and or sud...

Page 57: ... their normal effectiveness If the brakes are less effective than normal dry them by repeatedly applying the brakes while driving slowly until the brakes have regained their normal effectiveness RUNNING IN The future performance and reliability of the engine depends on the care and restraint exercised during its early life It is especially important to observe the following precautions during the ...

Page 58: ...ondition In the event of an engine malfunction particularly one involving engine misfire or other apparent loss of performance have the vehicle serviced promptly Do not turn off the engine or interrupt the ignition when the transmission is in gear and the vehicle is in motion Do not try to start the engine by pushing or towing the vehicle or coasting down a hill Do not idle the engine with any spa...

Page 59: ...ore fuel Keep a steady cruising speed Keep as constant a speed as road and traffic conditions will permit Keep the air cleaner clean A dirty air cleaner will cause the carburation system to supply too much fuel to the engine for the amount of air being supplied The result is waste of fuel due to incomplete combustion Keep weight to a minimum The heavier the load the more fuel the vehicle consumes ...

Page 60: ...60 844 74E MEMO ...

Page 61: ... DOMESTIC 844 74E DRIVING TIPS AND SAFE DRIVING 8 DRIVING TIPS AND SAFE DRIVING High Speed Driving 8 1 Driving on Hills 8 1 Driving on Slippery Roads 8 1 Driving on Wet Roads 8 2 Do s and Don ts for Safe Driving 8 3 ...

Page 62: ... speeds the vehicle may be affected by side winds Therefore reduce speed and be prepared for unexpected buffeting which can occur at the exits of tunnels when passing by a cut of a hill or when being overtaken by large vehicles etc DRIVING ON HILLS When climbing steep hills the car may begin to slow down and show a lack of power If this happens you should change to a lower gear so that the engine ...

Page 63: ...use oversized tyres or special shock absorbers and springs to raise jack up your vehicle This will change the handling characteristics After driving through water test the brakes while driving at a slow speed to see if they have maintained their normal effectiveness If the brakes are less effective than normal dry them by repeatedly applying the brakes while driving slowly until the brakes have re...

Page 64: ...quickly for it is dangerous and wastes fuel General driving 1 Be sure to stop before the stop light and stop sign When moving into the intersection without any traffic lights or signs drive slowly to confirm safety DO S AND DON TS FOR SAFE DRIVING 2 Always follow other vehicles at a safe distance in order to prevent a rear end collision should the vehicle ahead make a sudden stop 3 Turn ON the tur...

Page 65: ...e brake effectively Overuse of the footbrake may result in total brake failure 4 Avoid reckless high speed driving and try to drive at a safe speed suitable for the road conditions while maintaining a constant speed 5 The higher the speed the narrower the driver s visual range becomes In such a state it is difficult to anticipate any hazard and the driver feels much fatigued 6 Never do sharp handl...

Page 66: ...self a margin for safety during driving so that you can cope with erroneous or unexpected driving of other drivers For that observe the following Drive at a safe speed Maintain a sufficient distance between your vehicle and the vehicle ahead Don t force yourself to overtake other vehicles Don t make quick start hard steering or sudden stops Allow an ample time in the driving schedule Observe traff...

Page 67: ...Periodic Maintenance Schedule 9 1 Drive Belt 9 6 Engine Oil and Filter 9 6 Gear Oil 9 9 Engine Coolant 9 11 Windscreen Washer Fluid 9 12 Air Cleaner 9 12 Spark Plugs 9 13 Brakes 9 14 Steering 9 16 Clutch Pedal 9 16 Tyres 9 17 Battery 9 20 Fuses 9 20 Bulb Replacement 9 22 Wiper Blades 9 25 ...

Page 68: ...ufflers Do not allow smoking sparks or flames around gasoline or the battery Flammable fumes are present Do not get under your vehicle if it is supported only with the portable jack provided in your vehicle Be careful not to cause accidental short circuits between the positive and negative battery terminals Keep used oil coolant and other fluids away from children and pets Dispose of used fluids p...

Page 69: ...I R A I 1 1Water pump drive belt tension wear A I I I I R A I I R 2 Engine coolant level leakage I I I R I R I R I R 3 Engine oil API GRADE SF SG SH Oil filter R I R R R R R R R R 4 Cooling system hoses and connections leakage damage I I I I I I I I I I 5 Engine bolts All cylinder head and manifold fixings T T T T 6 Engine mounting loose damage T T T T 7 Valve clearance A A A A A 8 Camshaft timing...

Page 70: ...el lines connections leakage damage I I I 4 Fuel filter leakage I I I I I R I I I R CLUTCH AND TRANSMISSION 1 Clutch pedal play I I I I I I I I I I 2 Clutch slipping dragging or excessive damage I I I I I I I I I I 3 Manual Transmission Transfer and Differential oil level leakage I I I R I R I R I R DRIVE SHAFTS 1 Drive shafts boots bent of boots damage I I I I I I I I I BRAKE 1 Brake fluid level ...

Page 71: ...I I I I I I I 2 Suspension arms and knuckle supports loose damage I I I I I I I I I 3 Rear spring damage I I I I I I I I I 4 Shock absorbers oil leakage damage I I I I I I I I I I 5 All bolts and nuts loose T T T T T T T T T 6 Suspension arms and Tension rods I I I I I I I I I STEERING 1 Steering wheel play loose I I I I I I I I I I 2 All rods and arms loose damage wear I I I I I I I I I I ELECTRI...

Page 72: ...bbles I I I I I I I I I I 3 Tighten compressor mounting bolts T T T T T T T T T 4 Check all hose joints tighten if necessary I I I I I I I I I I 5 Check functioning of Recirc flap I I I I I I I I I I 6 Clean condenser with low pressure water C C C C C C C C C 7 Check belt for frayed edges change if necessary I I I I I I I I I 8 Check all mounting bolts I I I I I I I I I w w w w w WARNING All maint...

Page 73: ...e fan may not be moving it can automatically turn on without warning Make sure the drive belt tension is correct If the belt is too loose insufficient battery charging engine overheating or excessive belt wear can result When you press the belt with your thumb midway between the pulleys the belt deflection should be within the specification below w w w w w WARNING ENGINE OIL AND FILTER Specified o...

Page 74: ...add enough oil to raise the level to the upper limit Refilling Remove the oil filler cap and pour oil slowly through the filler hole to bring the oil level to the upper limit on the dipstick Be careful not to overfill Too much oil is almost as bad as too little oil After refilling start the engine and allow it to idle for about a minute Stop the engine wait for five minutes and check the oil level...

Page 75: ...nd gasket Tighten the plug to a torque of 5 0 kg m 36 5 lb ft Replace the oil filter 1 Using an oil filter wrench turn the oil filter counterclockwise and remove it 2 Using a clean rag wipe off the mounting surface on the engine where the new filter will be seated 3 Smear a little engine oil around the rubber gasket of the new oil filter 4 Screw on the new filter by hand until the filter gasket co...

Page 76: ...rtain coolant temperature condition When checking the oil level take care to keep hands clothing tie scarf etc away from the cooling fan To check the gear oil level use the following procedure 1 Park the vehicle on a level surface with the parking brake applied 2 Clean casing around oil level dipstick to remove risk of any loose dirt or debris entering the dipstick hole Remove the dipstick Specifi...

Page 77: ...level plug 1 Tightening torque 2 1 kg m 15 5 lb ft To check the gear oil level use the following procedure 1 Park the vehicle on a level surface with the parking brake applied 2 Clean casing around oil filler plug to remove risk of any loose dirt or debris entering oil filler plug hole Remove the oil filler plug 1 3 Feel the inside of the hole with your finger If the oil level comes up to the bott...

Page 78: ...160 C 30 F or below make the concentration at least 50 If the 50 concentration does not provide adequate protection agains freezing follow the instructions on the antifreeze container to obtain the desired freezing point Coolant Level Check Check the coolant level at the reservoir tank not at the radiator With the engine cool the coolant level should be between the FULL and LOW marks CAUTION It is...

Page 79: ...are frozen or with no fluid in the washer tank w w w w w WARNING AIR CLEANER If the air cleaner is clogged with dust there will be greater intake resistance resulting in decreased power output and increased fuel consumption Type 1 Take out the air cleaner case after opening bolts 2 and clamp 3 Take out the air cleaner element after unhooking the clamps 1 as shown in the illustration Type 2 T a k e...

Page 80: ...n the boot not on the cable itself Pulling on the cable can damage it When installing the spark plugs screw them in with your fingers to avoid stripping the threads Tighten with a torque wrench to 2 5 kg m 25 N m 18 5 lb ft for F8B engine CAUTION CAUTION and 1 5 Kg m 15 N m 10 5 lb ft for F8D engine Do not allow contaminants to enter the engine through the spark plug holes when the plugs are remov...

Page 81: ...spected by your MARUTI SUZUKI dealer BRAKES w w w w w WARNING Brake Fluid Check the brake fluid level by looking at the reservoir in the engine compartment Check that the fluid level is between the MAX and MIN lines If the brake fluid level is near the MIN line fill it up to the MAX line with MARUTI GENUINE brake fluid Failure to follow the guidelines below can result in personal injury or serious...

Page 82: ...brake system which should be inspected by your MARUTI SUZUKI dealer immediately Brake fluid can harm your eyes and damage painted surfaces Use caution when refilling the reservoir Do not use any fluid other than MARUTI GENUINE brake fluid Do not use reclaimed fluid or fluid that has been stored in old or open containers It is essential that foreign particles and other liquids are kept out of the b...

Page 83: ...ft to right and measuring the distance that it moves before you feel slight resistance The play should be between 0 30 mm 0 0 1 2 in Check that the steering wheel turns easily and smoothly without rattling by turning it all the way to the right and to the left while driving very slowly in an open area If the amount of free play is outside the specification or you find anything else to be wrong an ...

Page 84: ...Never underinflate or overinflate the tyres Underinflation can cause unusual handling characteristics or can cause the rim to slip on the tyre bead resulting in an accident or damage to the tyre or rim Overinflation can cause the tyre to burst resulting in personal injury Overinflation can also cause unusual handling characteristics which may result in an accident 2 Check that the depth of the tre...

Page 85: ...ation Pressure Label Hitting curbs and running over rocks can damage tyres and affect wheel alignment Be sure to have tyres and wheel alignment checked periodically by your MARUTI SUZUKI dealer 4 Check for loose wheel nuts 5 Check that there are no nails stones or other objects sticking into the tyres Your MARUTI SUZUKI is equipped with tyres which are all the same type and size This is important ...

Page 86: ...ot from driving 6 Install the new wheel and replace the wheel nuts with their cone shaped end facing the wheel Tighten each nut snugly by hand until the wheel is securely seated on the hub 7 Lower the jack and fully tighten the nuts 4 0 7 0 kg m 28 9 50 5 lb ft in a crisscross fashion with a wrench as shown in the illustration w w w w w WARNING Use MARUTI Genuine wheel nuts and tighten them to the...

Page 87: ...nect the cable from the negative terminal of the battery to help prevent discharge FUSES Batteries produce flammable hydrogen gas Keep flames and sparks away from the battery or an explosion may occur Never smoke when working in the vicinity of the battery When checking or servicing the battery disconnect the negative cable Be careful not to cause a short circuit by allowing metal objects to conta...

Page 88: ... MARUTI SUZUKI dealer w w w w w WARNING NOTE Make sure that the fuse box always carries two spare fuses w w w w w WARNING If the main fuse blows be sure to have your vehicle inspected by an authorized MARUTI SUZUKI dealer Always use a genuine MARUTI replacement Never use a substitute such as a wire even for a temporary repair or extensive electrical damage and a fire can result Fuse Box The fuse f...

Page 89: ...r right after being turned off This is true especially for halogen headlight bulbs Replace the bulbs after they become cool enough The headlight bulbs are filled with pressurized halogen gas They can burst and injure you if they are hit or dropped Handle them carefully The oils from your skin may cause a halogen bulb to overheat and burst when the lights are on Grasp a new bulb with a clean cloth ...

Page 90: ...unterclockwise and pull it out To install the holder push the holder in and turn it clockwise Two types small oval and round of bulb are used for these lights To remove and install a small oval bulb simply pull out or push in the bulb To remove a round bulb from a bulb holder push in the bulb and turn it counter clockwise To install a new bulb push it in and turn it clockwise You can access the in...

Page 91: ...e prop rod Front turn signal light Undo the two screws and remove the lens Side turn signal light Remove the lens by using a plain screw driver covered with a soft cloth Rear combination light tail stop turn signal etc Undo the screws that secure the housing and remove the housing 844 09 045 844 09 046 844 09 048 844 09 047 ...

Page 92: ...r blades To avoid scratching or breaking the window do not let the wiper arm strike the windshield while replacing the wiper blade The left and the right wiper arm assemblies are different from each other In case you have to remove the wiper arm assemblies for any reason remember not to interchange the two while fitting them back Wrong fitment may lead to windshield breakage WIPER BLADES CAUTION C...

Page 93: ...93 MARUTI 800 DOMESTIC 844 74E EMERGENCY SERVICE 10 EMERGENCY SERVICE Jacking Instructions 10 1 Jump Starting Instructions 10 2 Towing 10 4 Emergency Remedies 10 4 Warning triangle 10 5 ...

Page 94: ...l to be changed Make sure that the jack is raised at least 2 inches 51 mm before it contacts the vehicle Use of the jack when it is within 2 inches of being fully collapsed may result in failure of the jack 1 Park the vehicle securely on hard level ground 2 Choke the front and rear wheel diagonally opposite the wheel to be changed 3 Switch on the hazard warning flasher if your vehicle is in or nea...

Page 95: ...d When making jump lead connections be certain that your hands and the jump leads remain clear from pulleys belts or fans Batteries produce flammable hydrogen gas Keep flames and sparks away from the battery or an explosion may occur Never smoke when working in the vicinity of the battery If the booster battery you use for jump starting is installed in another vehicle make sure the two vehicles ar...

Page 96: ...ly the parking brakes fully on both vehicles 2 Turn off all vehicle accessories except those necessary for safety reasons for example headlights or hazard lights 3 Make jump lead connections as follows a Connect one end of the first jump lead to the positive terminal of the flat battery b Connect the other end to the positive terminal of the booster battery c Connect one end of the second jump lea...

Page 97: ...he engine to let it cool Do not open the bonnet when steam is present When the steam can no longer be seen or heard open the hood to see if the coolant is still boiling If it is you must wait until it stops boiling before you proceed If the Starter Does Not Operate 1 Try turning the ignition switch to the START position with the headlights turned on to determine the battery condition If the headli...

Page 98: ...s to remove the radiator cap when the water temperature is high because scalding fluid and steam may be blown out under pressure The cap should only be taken off when the coolant temperature has lowered w w w w w WARNING w w w w w WARNING To help prevent personal injury keep hands tools and clothing away from the engine cooling fan and air conditioner fan if equipped These electric fans can automa...

Page 99: ...s shown by arrow and lock the arms with each other with the clip provided in the right arm Open the botton stand in counter clock wise direction as shown by arrow 3 Position the warning triangle behind the vehicle on a plain surface Reverse the removal procedure for keeping inside the box EMERGENCY SERVICE 10 6 844 10 008 844 10 009 ...

Page 100: ...100 844 74E MEMO ...

Page 101: ...101 MARUTI 800 DOMESTIC 844 74E BODY WORK CARE 11 BODY WORK CARE Corrosion Prevention 11 1 Vehicle Cleaning 11 2 ...

Page 102: ...ine your vehicle for damage to the painted surfaces Should you find any chips or scratches in the paint touch them up immediately to prevent corrosion from starting If the chips or scratches have gone through to the bare metal have a qualified body shop make the repair Keep Passenger and luggage compar tments clean Moisture dirt or mud can accumulate under the floor mats and may cause corrosion Oc...

Page 103: ...inyl floor mats Ordinary dirt can be removed from vinyl with water or mild soap Use a brush to help loosen dirt After the dirt is loosened rinse the mat thoroughly with water and dry it in the shade Carpets Remove dirt and soil as much as possible with a vacuum cleaner Using a mild soap solution rub stained areas with a clean damp cloth To remove soap rub the areas again with a cloth dampened with...

Page 104: ...r with running water You may use a soft sponge or brush Do not use hard materials which can scratch the paint 3 Wash the entire exterior with a mild detergent or car wash soap using a sponge or soft cloth The sponge or cloth should be frequently soaked in the soap solution When using a commercial car wash product observe the cautions specified by the manufacturer Never use strong household deterge...

Page 105: ...105 MARUTI 800 DOMESTIC 844 74E GENERAL INFORMATION 12 GENERAL INFORMATION Vehicle Identification 12 1 ...

Page 106: ... chassis and or engine serial numbers are used to register the vehicle They are also used to assist your dealer when ordering or referring to special service information Whenever you have occasion to consult your MARUTI SUZUKI dealer remember to identify your vehicle with this number Should you find the number difficult to read you will also find it on the identification plate GENERAL INFORMATION ...

Page 107: ... and Dont s 13 2 Vehicle Starting Modes 13 4 Manual shut off valve 13 4 LPG Level indicator 13 4 Auto Mode 13 5 Petrol Mode 13 5 Forced LPG Mode 13 6 Spare Wheel Location 13 6 Spare Wheel Removal Procedure 13 6 LPG Filling 13 7 Petrol tank capacity 13 7 Periodic maintenance schedule 13 7 Maintenance Fuse 13 9 Kit Identification 13 9 Scrapping of LPG Tanks After Expiry Date 13 10 ...

Page 108: ...re Regulator 13 LPG Ventilation Hose 2 LPG Controller 8 High Pressure pipe joint 14 LPG Ventilation Duct 3 LPG Filter cum Solenoid Valve 9 Filler Valve 15 High Pressure Pipe 4 Stepper Motor 10 Multivalve 16 Wiring Harness 5 Low Pressure Hose 11 Gas Tight Housing 17 LPG Filling Pipe 6 Coolant Hose 12 LPG Tank 13 1 SIDE VIEW ...

Page 109: ...urther assistance You can drive the vehicle normally in petrol mode till the leakage is repaired Please check the position of the selector switch before starting the vehicle Always maintain some amount of petrol in petrol tank Always start the vehicle in Auto or petrol mode If engine does not start in Forced LPG mode start in Petrol mode and get the vehicle inspected by Maruti Suzuki authorized wo...

Page 110: ...ehicle Do not use Domestic LPG in your vehicle Never install any other gas cylinder in place of LPG Never install CNG or any other gas cylinder in place of LPG Never adjust setting of the LPG System The Auto LPG cylinder should never be repaired under any circumstances incase of any problem consult with Maruti Suzuki authorized workshop Never carry inflammable material near Auto LPG cylinder Never...

Page 111: ...low of LPG to engine In the close position LPG supply to the engine is stopped The shut off valve must be closed in case of any repair in the cylinder or any symptoms of LPG leakage TURN CLOCKWISE CLOSE TURN ANTICLOCKWISE OPEN 1 Orange LED Petrol 2 LPG Changeover switch 3 Green LED LPG 4 Level Indicators LPG LEVEL INDICATOR LED for indicating LPG quantity in the cylinder is installed on the dashbo...

Page 112: ...PG automatically when coolant temperature reaches around 40o C In warmed up condition changeover from petrol to LPG will happen after around 5 seconds of starting the engine Petrol Mode Vehicle can be started in Petrol mode with ignition switch ON and selecting Petrol Mode by gently pressing the mode selector switch 2 till ORANGE LED 1 glows At this stage vehicle will start and run on petrol only ...

Page 113: ...lp of spare wheel screw To remove the spare wheel unscrew spare wheel screw in anti clockwise direction using wheel wrench as show in the figure Reverse the above procedure for fitting the spare wheel Note During fitment of spare wheel position of the air filler nozzle should be facing upward and towards rear seat SPARE WHEEL LOCATION SPARE WHEEL REMOVAL PROCEDURE Forced LPG Mode CAUTION It is not...

Page 114: ... the joints checked for LPG leakage by applying soap solution on all the joints Do not fill more than 19 liters of LPG in tank CAUTION Your vehicle is fitted with petrol tank of 28 litres capacity Note The tank should always have sufficient quantity of petrol PETROL TANK CAPACITY Note The interval should be judged by odometer reading Over and above the regular maintenance schedule described in the...

Page 115: ...oolant Hoses Leakage Damage I I I I I I I I I I I I Drain Oil from Regulator C C C C C Low Pressurre Regulator Overhauling R R Diaphragm Replacement All Bolts and Nuts of LPR LPG Tank Solenoid Valve T T T T T T T T T T T T Idle RPM Idle CO HC Idle screw setting in Gas mode I I I I I I I I I I I I Ignition Wiring Damage Deterioration I I I I I I I I I I I Spark plugs Clean Adjust the Gap I I R I R ...

Page 116: ...our Maruti Suzuki authorized workshop w w w w w WARNING The LPG system is protected against short circuit overload using fuse 5A fitted in the fuse box under the driver s side of the dashboard as shown in the figure The changing of fuse should be only done at Maruti Suzuki Authorized Workshop 5 Ampere Fuse When this fuse blows off following symptoms may be observed All LED s on the switch will go ...

Page 117: ...vice by 1 Mechanical crushing 2 Piercing holes 3 Cutting the body into two or more pieces 4 For mechanical crushing piercing only pneumatic or hydraulic power should be used but not electrical tools 5 Once scrapped the parts may be recycled through the recycling waste disposal system Note Expiry date is mentioned on the LPG Tank of your vehicle LIQUID PETROLEUM GAS LPG ...

Page 118: ...118 844 74E MEMO ...

Page 119: ...und clearance 170 MASS WEIGHT UNIT Kg Petrol LPG Kerb mass weight Gross vehicle mass weight rating Seating Capacity ENGINE Type F8B Four stroke cycle 6 Valve water cooled SOHC or F8D Four stroke cycle 12 Valve water cooled SOHC Number of cylinders 3 Bore 68 5 mm Stroke 72 0 mm Piston displacement 796 cm3 Compression ratio 8 8 0 2 1 WITH A C WITHOUT A C 665 650 1000 1000 4 Person 4 Person WITH A C ...

Page 120: ...on plate light 12V 5W Reversing light 12V 21W WHEEL AND SUSPENSION Tyre size front and rear 145 70R12 Tyre pressures front rear 1 9 kg cm2 Suspension type front strut rear Leaf spring or Coil spring STEERING Toe in 1 2 mm CAPACITIES PETROL LPG Coolant 3 6 L 3 6 L Including reservoir tank Fuel tank 28 L 19 L 80 of cylinder capacity Engine oil 2 7 L Replacement with Oil Filter 2 7 L Replacement with...

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