🏷️ Basic Information

Make:

Suzuki

Model:

SJ Samurai

Generation:

SJ410/SJ413

Codes:

SJ410, SJ413

👋 Introduction

Market Position:

The Suzuki SJ Samurai is a compact, lightweight, and highly capable off-road vehicle known for its simplicity, ruggedness, and affordability. It carved a niche as a go-anywhere utility vehicle and a popular choice for recreational off-roading, overland adventures, and as a basic, dependable transportation.

Competitive Analysis:

Competed with other small 4x4s of its era, such as the Jeep CJ series (smaller variants), early Jeep YJ, Daihatsu Feroza, and some early compact SUVs. Its key differentiators were its low cost, extreme maneuverability, and exceptional off-road capability for its size.

Key Features:

Body-on-frame construction, solid front and rear axles, low-range transfer case, compact dimensions, excellent ground clearance, simple mechanicals, and durable reputation. Known for its distinct boxy styling and convertible top options.

📋 Manual Details

Years Covered:

1987, 1988

Page Count:

481

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine (Gasoline), Drivetrain (4WD, Transfer Case, Differentials), Transmission, Steering, Suspension (Front and Rear), Brakes (Front Disc, Rear Drum), Fuel System, Ignition System, Cooling System, Exhaust System, Electrical System (Wiring Diagrams, Components), Body (Interior and Exterior), Chassis

Engine Mechanical:

Detailed procedures for engine overhaul, piston and ring installation, crankshaft and connecting rod bearing replacement, cylinder head disassembly and reassembly, valve train adjustments.

Fuel And Emissions:

Carburetor overhaul, fuel pump testing, fuel line routing, emission control system component identification and basic troubleshooting.

Cooling System:

Radiator removal and installation, water pump inspection and replacement, thermostat testing, cooling fan operation, coolant capacity and type.

Ignition System:

Spark plug specifications, ignition timing adjustment, distributor component testing, coil resistance checks.

Transmission Manual:

Clutch assembly removal, inspection, and installation; transmission gear train disassembly and assembly; shift mechanism adjustment.

Transfer Case:

Transfer case disassembly, inspection of gears and chain, seal replacement, lubrication specifications.

Front Axle:

Front axle assembly, differential overhaul, axle shaft removal and installation, hub and bearing service, wheel alignment specifications.

Rear Axle:

Rear axle assembly, differential inspection and adjustment, axle shaft replacement, rear wheel bearing service.

Steering System:

Steering gear box overhaul and adjustment, steering linkage inspection, tie rod end replacement, power steering pump and hoses (if equipped).

Suspension Front:

Leaf spring removal and installation, shock absorber replacement, shackle and bushing inspection, kingpin service.

Brake System:

Front disc brake pad replacement, caliper service, rotor inspection; rear drum brake shoe replacement, wheel cylinder service, brake adjustment.

Electrical System:

Comprehensive wiring diagrams for all electrical circuits, component location charts, fuse and relay identification, starter and alternator service, battery charging system testing.

Body Interior:

Seat removal and installation, dashboard disassembly, door panel removal, interior trim component replacement.

Body Exterior:

Fender, hood, and grille removal and installation; door hinge adjustment; convertible top mechanism repair; bumper service.

Procedures Included:

Maintenance, Troubleshooting, Adjustments, Removal and Installation, Disassembly and Assembly, Component Testing, Diagnostics, Torque Specifications, Wear Limits, Special Tool Usage

Troubleshooting Charts:

Detailed troubleshooting guides based on symptoms for various systems, helping diagnose and resolve common issues.

Special Tool References:

Identification and illustration of specific Suzuki service tools required for various repair and adjustment procedures.

Torque Specifications:

Extensive lists of torque values for critical fasteners across all major components, ensuring proper assembly and safety.

Wear Limits:

Specific measurements and allowable wear limits for critical engine, drivetrain, and chassis components to determine when parts need replacement.

Technical Depth:

Comprehensive, step-by-step procedures with detailed illustrations, diagrams, and photos. Covers everything from basic adjustments to complete rebuilds, suitable for both professional mechanics and DIY enthusiasts.

Suspension Rear:

Rear leaf spring service, shock absorber replacement, shackle and bushing inspection.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Printable. High-resolution pages suitable for clear printing of text, diagrams, and illustrations.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Operating Systems Compatibility:

Windows, Mac, Linux OS. Requires Adobe Reader.

⚙️ Engine Specifications

Primary Engine:

G13A (1.3L SOHC 4-cylinder) - In many markets, this was the prevalent engine for the SJ Samurai during these years. Some regions may have had the SJ410 with the F10A (0.97L).

Horsepower:

Approximately 60-70 HP for the 1.3L engine, depending on specific tuning and market regulations.

Torque:

Approximately 70-80 lb-ft for the 1.3L engine.

Fuel System:

Carbureted (typically a two-barrel carburetor, e.g., Hitachi or Keihin).

Engine Code:

G13A (commonly found in 1.3L models)

Bore And Stroke:

Approximately 74 mm x 77 mm for the G13A engine.

Compression Ratio:

Around 8.4:1 to 9.2:1, depending on specific engine variant and market.

Oil Capacity With Filter:

Approximately 3.2 - 3.5 US quarts (3.0 - 3.3 liters).

🔧 Transmission

Standard Transmission:

5-speed manual transmission.

Optional Transmission:

3-speed automatic transmission (less common, often market-specific).

Features:

Equipped with a 2-speed transfer case for 2WD High, 4WD High, and 4WD Low range. Known for its robust and simple mechanical operation.

📐 Dimensions

Wheelbase:

Approx. 80 inches (2030 mm) for standard wheelbase models.

Overall Length:

Approx. 138 inches (3505 mm).

Overall Width:

Approx. 60 inches (1525 mm).

Overall Height:

Approx. 63-65 inches (1600-1650 mm), depending on roof type.

Ground Clearance:

Approx. 7.5-8.0 inches (190-203 mm), varies with tire size and suspension.

Approach Angle:

Approx. 42 degrees

Departure Angle:

Approx. 40 degrees

Breakover Angle:

Approx. 125 degrees

Curb Weight:

Approx. 1800-2100 lbs (816-953 kg).

Gross Vehicle Weight Rating:

Approx. 2800-3000 lbs (1270-1360 kg).

🛡️ Safety Features

Crash Test Ratings:

As a 1980s era vehicle, it predates modern standardized crash testing by NHTSA and IIHS. Safety features were minimal compared to contemporary vehicles.

Active Safety Features:

Standard 4-wheel drive for improved traction, basic anti-lock braking system (ABS) was not a common feature for this model year.

Passive Safety Features:

Lap belts were standard. Some models may have offered optional shoulder belts. Minimal structural safety features compared to modern vehicles.

💡 Technology Features

Infotainment Features:

Basic analog gauges, AM/FM radio (optional), and manual climate controls. Technology was very rudimentary, focusing on mechanical function over electronic features.

Driver Assistance Features:

None. Features like traction control, stability control, adaptive cruise control, or advanced driver-assistance systems (ADAS) were non-existent.

Connectivity Features:

No modern connectivity features like Bluetooth, USB ports, or smartphone integration. Power windows and locks were typically manual or optional on higher trims.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 to 5,000 miles (5,000 to 8,000 km) or every 6 months, whichever comes first.

Tune Up Interval:

Spark plugs, distributor cap/rotor, and fuel filter generally every 15,000-30,000 miles. Timing belt replacement (if applicable to engine variant) around 60,000 miles or as per manual.

Engine Oil Specification:

API SF or SG quality, viscosity typically 10W-30 or 10W-40 (consult manual for specific temperature ranges and capacities).

Transmission Fluid Specification:

Manual: GL-4 hypoid gear oil, SAE 75W-90 or 80W-90. Automatic: DEXRON II or equivalent.

Coolant Specification:

Ethylene glycol-based antifreeze (50/50 mix with distilled water) for freeze protection and corrosion inhibition.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Specification:

If equipped with power steering, typically ATF DEXRON II or equivalent.

Common Issues:

Rust and corrosion (especially on chassis, body panels, and frame), carburetor tuning and maintenance, potential clutch wear, aging electrical components, worn suspension bushings, starter motor issues, and rear main seal leaks.

Oil Filter Part Number:

Commonly cross-references with Champion C110, Fram PH2, WIX 51515 (verify for specific model).

📚 Vehicle History

Brand Heritage:

Suzuki, a Japanese multinational corporation, has a long history in manufacturing motorcycles and automobiles. They are renowned for producing small, efficient, and rugged vehicles, often with a focus on practicality and off-road capability.

Model Evolution:

The SJ Samurai (known as the Suzuki Jimny outside North America for many generations) lineage began in the 1970s. The SJ series evolved from earlier models like the LJ. The 1987-1988 model year represents a significant update and refinement of the SJ platform, introducing improved engines and features over earlier iterations. It was sold globally under various names and configurations.

Production Years:

The SJ series spanned from the late 1970s through the early 1990s. The 1987-1988 models were part of the later production run of the SJ generation.

Manufacturing Locations:

Primarily manufactured in Japan, with some production or assembly occurring in other Suzuki global facilities.

🏆 Awards & Recognition

Recognitions:

While specific awards for the 1987-1988 SJ Samurai are not widely documented in the same way as modern vehicles, the model series is widely recognized for its enduring popularity, off-road prowess, and its status as a cult classic among enthusiasts.