Market Position:
Compact, rugged, off-road focused utility vehicle, popular for its affordability, simplicity, and go-anywhere capability. Often utilized for light trail use, off-roading, and as a basic utility vehicle.
Target Audience:
Enthusiasts seeking an affordable, capable off-road vehicle, DIY mechanics, and owners who value simplicity and reliability.
Competitive Analysis:
Competed against other small off-roaders and compact SUVs of the era, though its body-on-frame construction and leaf-spring suspension set it apart as a more traditional and rugged option compared to unibody crossovers.
Key Features:
Lightweight construction, part-time 4WD system, low-range transfer case, compact dimensions, durable and simple mechanicals, high ground clearance, excellent maneuverability.
Coverage Areas:
Diagnosis, maintenance adjustments, service operations, component replacement, disassembly, and assembly of all major vehicle systems.
Page Count:
Estimated 800-1200 pages (typical for comprehensive FSMs of this era)
Manual Type:
Factory Service Manual (FSM)
Format:
PDF Download (Software Database Download)
Compatibility:
Compatible with most devices capable of opening PDF files (computers, tablets, smartphones).
Systems Covered:
Engine (G13A, G13B), Fuel System, Ignition System, Cooling System, Exhaust System, Clutch, Transmission (4-speed, 5-speed manual), Transfer Case, Drive Shafts, Front Axle, Rear Axle, Suspension (Front Leaf Spring, Rear Leaf Spring), Steering, Brakes (Front Disc, Rear Drum), Electrical System (Charging, Starting, Lighting, Accessories), Body, Chassis, HVAC (if equipped).
Body And Chassis:
Includes procedures for body panel removal, door mechanisms, seat adjustments, chassis lubrication, frame inspection and repair.
Suspension And Steering:
Detailed instructions for leaf spring inspection, replacement, shackle adjustment, front axle service, kingpin inspection, steering linkage adjustment, and power steering system maintenance (if equipped).
Procedures Included:
General maintenance, lubrication, engine tune-up, fuel injection/carburetor service, ignition timing, valve adjustment, cylinder head removal/installation, piston and connecting rod service, crankshaft and bearing service, transmission overhaul, clutch replacement, transfer case service, brake system bleeding and repair, suspension component replacement, steering system adjustments, electrical component testing and replacement, body panel alignment and repair, diagnostic procedures for all systems.
Troubleshooting Charts:
Extensive troubleshooting guides and diagnostic flowcharts for engine performance, electrical issues, and drivetrain problems.
Engine Rebuild:
Comprehensive procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, valves), cylinder honing, crankshaft and camshaft service, and reassembly with torque specifications.
Technical Depth:
Comprehensive. Covers from basic adjustments and fluid changes to full engine and transmission rebuilds, detailed wiring diagrams, and troubleshooting charts.
Wiring Diagrams:
Detailed electrical wiring diagrams for all circuits, components, and systems, crucial for diagnosing electrical faults.
Primary Engine:
1.3L (1324 cc) SOHC 8-valve inline-4 cylinder (G13A for 1986, G13B for later 1987 models)
Horsepower Approx:
63-70 HP @ 5500-6000 RPM (depending on specific engine code and market)
Torque Approx:
70-75 lb-ft @ 3000-3500 RPM (depending on specific engine code and market)
Fuel System:
Carbureted (Hitachi or Mikuni) for most 1986 and early 1987 models; Fuel Injection (MPI) introduced on some late 1987 models.
Engine Codes Covered:
G13A (8-valve), G13B (12-valve DOHC, introduced in later SJ413/Samurai models, though less common in early US 1986-87 models which primarily used G13A)
Wheelbase In:
80.3 inches (2040 mm)
Length In:
142.5 inches (3620 mm) (Soft Top)
Width In:
60.0 inches (1525 mm)
Height In:
64.8 inches (1645 mm) (Soft Top)
Curb Weight Lbs:
Approx. 2050-2150 lbs (930-975 kg)
Gross Vehicle Weight Rating Lbs:
Approx. 3000 lbs (1360 kg)
Oil Change Interval Miles:
Every 3,000 miles or 3 months
Transmission Fluid Change Miles:
Every 30,000 miles or 24 months
Transfer Case Fluid Change Miles:
Every 30,000 miles or 24 months
Spark Plug Replacement Miles:
Every 15,000-30,000 miles (check specific plug type recommended)
Engine Oil Specification:
API SG or higher, SAE 10W-30 or 10W-40 (check manual for climate variations)
Transmission Fluid Specification:
API GL-4, SAE 75W-90 or 80W-90 gear oil
Transfer Case Fluid Specification:
API GL-4, SAE 75W-90 or 80W-90 gear oil
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mix with distilled water
Brake Fluid Specification:
DOT 3
Clutch Fluid Specification:
DOT 3 (if hydraulic clutch, check specific application)
Known Issues:
Rust on body panels and frame (especially common in certain climates), carburetor tuning issues, clutch wear, leaf spring fatigue, occasional electrical gremlins, overheating if cooling system is not maintained.
Brand Heritage:
Suzuki has a long history of producing small, robust, and affordable vehicles, often with a focus on off-road capability and practicality. The Samurai is a direct descendant of the earlier Jimny line.
Model Evolution:
The SJ410/SJ413 Samurai represented the second generation of Suzuki's globally successful compact 4x4. It succeeded the LJ series and was later replaced by the more refined Sidekick/Vitara in many markets. The 1986-1987 models were part of the initial introduction into markets like North America, featuring the reliable G13A/G13B engines.
Production Period:
Second generation (SJ series) globally from 1981; North American market introduction around 1985/1986.
