Vehicle Segment:
Compact SUV / Off-Road Vehicle
Key Selling Points:
Go-anywhere capability, rugged simplicity, affordability, iconic styling.
Primary Competitors:
Jeep CJ/Wrangler (smaller variants), Toyota Land Cruiser (early models), Mitsubishi Pajero (early models), Daihatsu Rocky.
Off Road Capability:
Body-on-frame construction, solid axles, selectable 4WD, low-range transfer case, high ground clearance.
Powertrain Philosophy:
Simple, durable, carbureted gasoline engine prioritizing reliability over high performance.
Manual Value Proposition:
Provides comprehensive factory-level information essential for maintaining and repairing this iconic, relatively simple vehicle.
Engine Mechanical:
Engine assembly, disassembly, inspection, repair, torque specifications, cooling system, lubrication system, fuel system (carburetor).
Engine Electrical:
Ignition system, starting system, charging system, sensors, wiring diagrams, troubleshooting.
Transmission:
Manual transmission (4-speed and 5-speed variants), transfer case, clutch system, repair procedures, specifications.
Drivetrain:
Front and rear axles, drive shafts, universal joints, differentials, hubs, wheel bearings.
Suspension:
Front and rear suspension systems (leaf springs), shock absorbers, bushings, alignment specifications.
Steering:
Steering column, steering gear, tie rods, power steering system (if equipped), troubleshooting.
Brakes:
Front disc brakes, rear drum brakes, hydraulic system, parking brake, repair and adjustment procedures, specifications.
Body And Chassis:
Frame construction, body panels, doors, hood, tailgate, interior trim, exterior trim, glass, weatherstripping.
Electrical Accessories:
Lighting system, wipers, horn, instrumentation, interior lights, accessory circuits.
Heating And Ventilation:
HVAC system components, blower motor, heater core, vent controls, repair and diagnosis.
Preventive Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, lubrication points, tune-up procedures.
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting guides, electrical issue diagnosis.
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul for all major systems.
Technical Specifications:
Detailed torque values, clearances, fluid capacities, electrical resistance values, pressure specifications.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Diagnostic Capabilities:
Advanced diagnostics for mechanical and electrical systems, including symptom analysis and component testing.
Rebuild Procedures:
Complete engine, transmission, and differential rebuild procedures with detailed part specifications and tolerances.
Adjustment Procedures:
Detailed instructions for adjusting brakes, clutch, ignition timing, carburetor settings, and suspension alignment.
Transmission Type:
Manual
Gear Ratios 4 Speed:
First: ~3.15, Second: ~1.82, Third: ~1.30, Fourth: 1.00, Reverse: ~3.56 (Typical values, consult manual for exact ratios)
Gear Ratios 5 Speed:
First: ~3.45, Second: ~1.95, Third: ~1.40, Fourth: 1.00, Fifth: 0.85, Reverse: ~3.03 (Typical values, consult manual for exact ratios)
Transfer Case Type:
2-speed manual transfer case with 2WD/4WD selection (High/Low range)
Clutch Type:
Dry single plate (mechanical actuation)
Transmission Fluid Type:
API GL-4 gear oil, SAE 75W-90 or 80W-90 (Consult manual for precise specification)
Transfer Case Fluid Type:
API GL-4 gear oil, SAE 75W-90 or 80W-90 (Consult manual for precise specification)
Wheelbase:
Approximately 80.0 inches (2030 mm)
Length:
Approximately 142.5 inches (3620 mm) (Soft Top), 143.7 inches (3650 mm) (Hardtop)
Width:
Approximately 60.0 inches (1525 mm)
Height:
Approximately 63.7 inches (1618 mm) (Hardtop), 64.2 inches (1630 mm) (Soft Top)
Curb Weight:
Approximately 2000-2200 lbs (907-1000 kg)
Gross Vehicle Weight Rating Gvwr:
Approximately 3100 lbs (1406 kg)
Standard Tire Size:
205/75R15 or similar (consult manual for exact spec and options)
Wheel Bolt Pattern:
5x5.5 inches (139.7 mm)
Wheel Size:
15 x 5.5 inches (Steel or optional alloy)
Engine Oil Change:
Every 3,000-5,000 miles or 6 months (consult manual for exact interval based on driving conditions).
Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 12,000-15,000 miles or annually (or more frequently in dusty conditions).
Spark Plug Replacement:
Every 20,000-30,000 miles (depending on plug type, consult manual).
Transmission Fluid Change:
Every 30,000-50,000 miles or 2-3 years (consult manual).
Transfer Case Fluid Change:
Every 30,000-50,000 miles or 2-3 years (consult manual).
Differential Fluid Change:
Every 30,000-50,000 miles or 2-3 years (consult manual).
Engine Oil Type:
API SF/SG, SAE 10W-30 or 10W-40 (consult manual for seasonal recommendations).
Engine Oil Capacity:
Approximately 3.5 quarts (3.3 liters) with filter change (verify in manual).
Coolant Type:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water.
Coolant Capacity:
Approximately 5.0 quarts (4.7 liters) (verify in manual).
Brake Fluid Type:
DOT 3 or DOT 4.
Common Wear Items:
Clutch components, tie rod ends, ball joints, wheel bearings, leaf spring bushings, exhaust system, carburetor performance degradation.
Rust Prone Areas:
Body tub, fenders, rocker panels, frame rails (especially in salt-belt regions).
Carburetor Tuning:
Carburetors can require periodic adjustment or rebuilding due to age and wear, affecting fuel economy and idle stability.
Transfer Case Chain Stretch:
Potential for chain stretch in the transfer case, leading to 'slop' in the drivetrain, though less common than in later SJ413 models.
Suzuki Off Road Legacy:
Suzuki has a long history of producing lightweight, capable off-road vehicles, including the earlier Jimny/Kei trucks and LJ series.
Predecessor:
Suzuki SJ series (SJ410, SJ413) which was sold globally under various names (Jimny, Samurai, Sierra, etc.). The SJ410 is an evolution of earlier short-wheelbase models.
Distinction:
The SJ410 designation specifically refers to the 1.3L carbureted engine variant of the Suzuki Samurai/Sierra.
Manufacturing Locations:
Primarily Japan, with assembly plants in other countries (e.g., Spain, India) for various markets.
Market Introduction As Samurai:
Introduced to the North American market in 1985/1986, gaining popularity for its affordability and off-road prowess.
