Suzuki Carry Repair Manual for 1985–91 Models (P/N 31705)

• Configuration coverage: Documents the carbureted, water-cooled four-cylinder SOHC configuration, including SK410 van fuel-system routing, four- and five-speed manual transmissions, right- and left-hand steering layouts, van and low-floor brake routing, and suspension with or without a stabilizer bar.
• Engine repair depth: Covers engine-and-transmission removal, complete engine disassembly and reassembly, cylinder-head and valve work, camshaft and timing-belt service, pistons and rings, connecting rods, crankshaft bearings, flywheel, oil pump, strainer, filter, and lubrication-circuit testing.
• Fuel, emissions, and cooling: Details one-barrel Mikuni carburetor removal and overhaul, air-cleaner service, float, choke-opener, and BVSV checks, fuel-pump/filter/tank work, PCV testing, both square control-valve and round check-valve charcoal-canister layouts, radiator and water-pump repair, thermostat inspection, hose service, and cooling-system flushing.
• Driveline procedures: Separates the four-speed and five-speed gearbox repair sections and includes clutch, shift-control cable, transmission, propeller-shaft, and differential work. Differential coverage extends to pinion-bearing preload, bevel-gear backlash, tooth-contact checks, and shim selection.
• Chassis, brake, and body work: Includes front and rear suspension, hubs and wheel bearings, steering-gear overhaul and alignment, front disc and rear drum brakes, master cylinder, optional vacuum booster and DSP valve, brake-line bleeding, doors, window regulators, latches, and chassis/body dimensions.
• Electrical diagnosis: Covers breaker-point ignition and timing, distributor service, starter disassembly and performance tests, alternator and battery checks, headlights, turn and hazard circuits, wipers, fuel and temperature gauges, rear defogger, fuse-box layouts, and system-specific troubleshooting charts.
• Workshop reference: Provides the maintenance schedule, required service materials, special-tool catalog, standard shop practices, metric fastener and conversion charts, torque tables, capacities, wear limits, adjustment data, and electrical test specifications. Document 31705 contains 404 PDF pages across 26 section files plus a separate van-type wiring-diagram JPG.

Manual Scope

The powertrain material is built around a 970 cc, four-stroke gasoline engine with a crossflow SOHC cylinder head, timing-belt camshaft drive, wet-sump pressure lubrication, and a one-barrel horizontal-draft carburetor. It does not include repair chapters for electronic fuel injection, automatic transmissions, or a four-wheel-drive transfer system. Because the procedures assume access to pullers, installers, gauges, a press, and accurate measuring equipment, this set is suited to experienced mechanics and well-equipped owners rather than first-time repair work.

Identification and Service Data

The general section shows the body number on the upper surface of the right-hand tire housing beneath the seat and the engine number on the right-hand skirt of the cylinder block below the carburetor. The closing Service Data section consolidates engine, lubrication, clutch/transmission, cooling, differential, suspension, carburetor, steering, brake, and electrical specifications, including component torque tables and inspection limits.

Special Tools and Diagrams

The illustrated tool catalog identifies the carburetor adjuster 09913-17910, compression gauge 09915-64510, oil-pressure gauge 09915-77310, vacuum-pump gauge 09917-47910, differential preload checking tool 09922-75221, and booster diaphragm remover 09951-85510, along with the pullers, installers, reamers, and holding fixtures used throughout the repair chapters.

Diagram coverage includes the engine lubrication circuit; carburetor and fuel-vapor flow layouts; cooling-water circulation; heater-blower and ignition circuits; van and low-floor brake piping; and the standalone van-type wiring diagram with wire-color codes.

Repair Cautions

The carburetor overhaul section warns that drills or wire can damage calibrated fuel passages and metering jets, while careless handling can damage the plastic float assembly. The propeller shaft must not be welded, dropped, or intentionally heated because related parts can be damaged or the shaft can become eccentric and cause vibration.

Fuel-system service calls for battery isolation, release of fuel-tank vapor pressure, and strict control of flames and sparks; the fuel-pump test specifically uses kerosene rather than gasoline. The brake section warns that wheel-brake parts may contain asbestos fibers, prohibits dust-producing cleaning methods, and requires the specified glycol-based fluid to avoid hydraulic-system damage.