Segment:
Compact SUV / Off-Road Vehicle
Target Audience:
Enthusiasts, off-roaders, and DIY mechanics seeking authentic factory repair data.
Competitors 1986:
Jeep Wrangler (YJ), Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner.
Vehicle Appeal:
Go-anywhere capability, compact size, rugged simplicity, excellent off-road articulation.
Manual Value Proposition:
Provides the definitive, factory-accurate information needed for proper maintenance and repair, crucial for preserving the Samurai's unique capabilities.
General Coverage:
Comprehensive service, repair, and maintenance for the 1986 Suzuki Samurai.
Specific Systems:
Engine, Fuel System, Exhaust, Cooling, Lubrication, Clutch, Transmission, Transfer Case, Drive Axles, Suspension, Steering, Brakes, Electrical System, Body, Chassis, Heater, Air Conditioning (if applicable).
Type:
Factory Service Manual / Repair Manual
Format:
Digital PDF (Searchable)
Powertrain:
Detailed coverage of engine (G13A 1.3L I4), fuel injection (if applicable), ignition, cooling, lubrication, exhaust, clutch, manual transmission, and transfer case.
Drivetrain:
Covers front and rear drive axles, differentials, driveshafts, universal joints, and four-wheel-drive engagement systems.
Suspension Steering:
Detailed information on leaf spring suspension, shock absorbers, steering gearbox, linkages, and alignment specifications.
Brakes:
Front disc and rear drum brake systems, including hydraulic components, brake linings, rotors, drums, and parking brake system.
Electrical:
Complete wiring diagrams, fuse box layout, component testing, charging system, starting system, lighting, and instrument panel.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, tune-ups, fluid checks and changes, and lubrication points.
Diagnostics:
Troubleshooting guides for common problems, diagnostic flowcharts, and specific symptom analysis.
Repair Rebuild:
Step-by-step instructions for major component removal, installation, disassembly, and reassembly (e.g., engine overhaul, transmission rebuild).
Bodywork:
Body panel repair, door mechanisms, glass replacement, and interior trim removal/installation.
Specifications Data:
Torque specifications, clearances, wear limits, and diagnostic data for all major systems.
Depth:
Expert level, covering complete vehicle overhaul, complex diagnostics, and factory-level repair procedures.
Engine Type:
Inline 4-Cylinder, SOHC
Displacement:
1.3 Liters (1324 cc)
Horsepower Net:
Approx. 63-64 hp @ 5500 rpm (Varies by market/tuning)
Torque Net:
Approx. 73-75 lb-ft @ 3500 rpm (Varies by market/tuning)
Fuel Delivery:
Carbureted (e.g., Hitachi DCZ or similar twin-choke carburetor) or early multi-point fuel injection (MPI) on some SJ413 variants.
Fuel Type:
Unleaded Gasoline (Regular Octane)
Cooling System:
Water-cooled, pressurized system
Oil Capacity W Filter:
3.7 US Quarts (3.5 Liters)
Recommended Oil Viscosity:
10W-30 or 10W-40 API SG or later
Transmission Type:
5-Speed Manual
Transmission Type:
3-Speed Automatic (Less Common)
Transfer Case:
2-Speed Transfer Case with Part-Time 4WD (High/Low range)
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or 80W-90 Gear Oil
Transfer Case Fluid:
API GL-4 SAE 75W-90 or 80W-90 Gear Oil
Wheelbase:
80.0 inches (2032 mm)
Length:
142.5 inches (3620 mm)
Width:
60.6 inches (1540 mm)
Height:
67.1 inches (1705 mm) (Soft Top)
Curb Weight:
Approx. 2000-2200 lbs (907-998 kg)
Gross Vehicle Weight Rating:
Approx. 3000-3300 lbs (1361-1497 kg)
Towing Capacity:
Not officially rated for heavy towing; typically limited to accessory trailering or light utility trailers.
NHTSA Rollover Resistance:
2 Stars (Static Stability Factor based)
Braking System:
Front ventilated discs, rear drums. Manual adjusting rear brakes.
Steering Features:
Recirculating ball steering system (non-power assist standard).
Restraints:
Lap and shoulder belts (front), lap belts (rear/side).
Body Construction:
Body-on-frame construction, rugged chassis.
Audio System:
Basic AM/FM Radio, often with cassette player. Aftermarket upgrades are common.
Instrument Cluster:
Basic gauges: Speedometer, Fuel Gauge, Temperature Gauge, Oil Pressure Warning Light, Battery Warning Light.
Connectivity Features:
None from factory. Often upgraded with aftermarket Bluetooth/audio systems.
Oil Change Interval:
Every 3,000 - 5,000 miles or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 - 30,000 miles or annually.
Spark Plug Replacement:
Every 30,000 - 45,000 miles.
Timing Belt Replacement:
Not applicable (engine uses a timing chain).
Coolant Type:
Ethylene Glycol based coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Power Steering Fluid:
N/A (Manual Steering)
Common Complaints:
Rust (frame, body panels, fenders), carburetor issues (tuning, leaks), clutch wear, differential whine, steering looseness, potential for overheating if cooling system is neglected, suspension wear (bushings, leaf springs).
Electrical Quirks:
Aging wiring harnesses, starter issues, alternator problems.
Manufacturer:
Suzuki Motor Corporation (Japan)
Predecessor:
Suzuki Jimny (SJ series, earlier iterations)
Development Focus:
Designed as a lightweight, highly capable off-road vehicle, often referred to as a 'mini-ute' or 'compact 4x4'.
Production Years:
1985-1998 (North America)
Manufacturing Locations:
Japan (primary), Assembly in other regions sometimes occurred.
Sales Performance:
Achieved significant popularity in North America during the late 1980s for its affordability and off-road prowess, though later faced criticism regarding safety standards.
Off Road Accolades:
Widely recognized for its exceptional off-road capability relative to its size and price point during its era.
Consumer Reports Rating:
Mixed, often citing reliability concerns and safety limitations, despite positive marks for off-road performance.
Emissions Standards:
Compliant with 1986 US Federal emissions standards (catalytic converter equipped).
