Suzuki SIERRA SJ410 SJ410V SJ410K SJ40 Workshop Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Sierra SJ410 Model Variant: SJ410, SJ410V, SJ410K, SJ40 Also Known As: Jimny 1000, Samurai (early models), Caribbean, Katana, Potohar, Santana, Chevrolet Samurai, Holden...

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标签: Car Cars Featured Maruti Suzuki SIERRA SJ410 SJ40 SJ410K SJ410V Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Sierra SJ410

Model Variant:

SJ410, SJ410V, SJ410K, SJ40

Also Known As:

Jimny 1000, Samurai (early models), Caribbean, Katana, Potohar, Santana, Chevrolet Samurai, Holden Drover, Maruti Gypsy

Generation

Generation Code:

SJ Series

Codes

Chassis Codes:

SJ410, SJ410V, SJ410K, SJ40

Engine Codes:

👋 Introduction

Market Position

Positioning:

Specialized workshop manual for enthusiasts and mechanics working on the robust and capable Suzuki SJ410 platform, differentiating from widely available, potentially less accurate Samurai SJ413 manuals.

Competitive Analysis

Differentiation:

Directly addresses the common availability of the SJ413 manual by emphasizing its focus on the distinct SJ410, SJ410V, SJ410K, and SJ40 variants.

Key Features

Comprehensiveness:

Over 300 pages of structured content, including troubleshooting, detailed system breakdowns, and maintenance schedules.

Target Audience:

Suzuki technicians, mechanics, and dedicated owners seeking authentic factory repair information.

📋 Manual Details

Coverage Areas

Primary Coverage:

Suzuki Sierra SJ410, SJ410V, SJ410K, SJ40 models

Supplementary Coverage:

SJ410 Supplementary Manual, SJ410 SJ410V SJ410K Supplementary Manual

Page Count

Estimated Pages:

Manual Type

Type:

Factory Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

F10A 1.0L engine, including carburetor, air cleaner, fuel pump, fuel filter

Cooling System:

Engine cooling system, car heater

Ignition Charging Starting:

Ignition system, starter motor, charging system

Drivetrain:

Clutch, gear shifting control, transmission, transfer gearbox, propeller shafts, differential

Suspension Steering Brakes:

Suspension, steering system, brakes

Body Electrical:

Door systems, body electrical equipment

Procedures Included

General Repair:

General repair procedures, special tools, and service materials

Troubleshooting:

Comprehensive troubleshooting guides

Maintenance:

Maintenance schedules and procedures

Technical Depth

Depth:

Designed to meet the needs of Suzuki technicians worldwide, indicating a high level of technical detail for diagnostics, repair, and overhaul.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text, common for professional PDF manuals.

Print Quality

Quality:

High quality, 'the real deal', suggesting clear diagrams and text.

Binding Type

Binding:

N/A (PDF Download)

Paper Type

Paper:

N/A (PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, SOHC

Engine Code:

Displacement:

970 cc (59 cu in)

Bore X Stroke:

65.5 mm x 72.0 mm

Performance

Horsepower Net Estimated:

Approx. 45-60 HP (varies by market and tuning)

Torque Net Estimated:

Approx. 70-80 lb-ft (varies by market and tuning)

Fuel System

Fuel Delivery:

Carbureted

Carburetor Type Typical:

Hitachi DCZ or similar single-barrel downdraft carburetor

Ignition System

Ignition Type:

Distributor-based, points or electronic ignition (depending on specific year/market)

Cooling System

Cooling Method:

Liquid-cooled

Engine Components

Valve Train:

SOHC (Single Overhead Camshaft)

🔧 Transmission

Standard

Type:

4-speed manual transmission

Optional

Type:

5-speed manual transmission (likely on later models or specific markets)

Features

Transfer Case:

2-speed transfer case with selectable 4WD (4H, 4L, 2H)

Fluid Requirements

Transmission Fluid Type:

API GL-4 SAE 80W or 80W-90 gear oil (specific grade may vary, consult manual)

Transfer Case Fluid Type:

API GL-4 SAE 80W or 80W-90 gear oil (specific grade may vary, consult manual)

📐 Dimensions

Exterior

Wheelbase:

Approx. 2030 mm (80 inches) for SWB models

Length Swb:

Approx. 3200 mm (126 inches)

Width Swb:

Approx. 1500 mm (59 inches)

Height Swb Soft Top:

Approx. 1700 mm (67 inches) (varies with top)

Weights

Curb Weight Typical:

Approx. 850-950 kg (1874-2094 lbs)

Gross Vehicle Weight Rating Gvwr:

Consult specific model documentation, typically around 1500 kg (3307 lbs)

🛡️ Safety Features

Ratings

Crash Test Results:

Older vehicle design, pre-modern crash safety standards. Ratings not comparable to contemporary vehicles.

Active Features

Braking System:

Front disc brakes, rear drum brakes

Steering System:

Recirculating ball steering, typically manual steering (power steering optional on some variants).

Passive Features

Seat Belts:

Standard seat belts (lap/shoulder)

Body Structure:

Body-on-frame construction, known for durability and off-road capability rather than advanced passive safety features.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio, often with a single-DIN cassette player. Aftermarket upgrades are common.

Driver Assistance

Features:

Minimal to none. Focus is on mechanical simplicity and off-road capability. Features like ABS, airbags, or traction control are not present.

Connectivity

Features:

No integrated connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first (refer to manual for exact specification).

Transmission Fluid Interval:

Every 40,000 km (24,000 miles) or 24 months (refer to manual for exact specification).

Differential Fluid Interval:

Every 40,000 km (24,000 miles) or 24 months (refer to manual for exact specification).

Fluid Specifications

Engine Oil Type:

API SG/SH SAE 10W-30 or 10W-40 (refer to manual for exact specification and viscosity based on climate).

Coolant Type:

Ethylene glycol based antifreeze/coolant, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch wear, exhaust system rust, suspension bushings, carburetor tuning, starter motor reliability, and rear main seal oil leaks.

Engine Specifics:

F10A engine is generally robust but can suffer from carbon buildup, leading to rough idling and reduced power if not maintained. Carburetor requires periodic adjustment.

Filter Part Numbers

Oil Filter:

OEM Part Number 16510-82703 (example, may vary, consult manual or parts catalog).

Air Filter:

OEM Part Number 13780-82700 (example, may vary, consult manual or parts catalog).

📚 Vehicle History

Brand Heritage

Suzuki Offroad Legacy:

Part of Suzuki's long history of producing compact, capable off-road vehicles, building on the legacy of the LJ series.

Model Evolution

Predecessor:

Suzuki LJ series (LJ80, LJ50)

Successor:

Suzuki Jimny (SJ and JA series onwards, then JB series)

Production

Production Years:

1981-1998 (for SJ410 series)

Manufacturing Locations:

Japan, India (Maruti Suzuki), Pakistan, and other licensed manufacturers globally.

Key Markets:

Global, particularly strong in Australia, Asia, Europe, and North America (as Samurai).

🏆 Awards & Recognition

Recognitions

Offroad Capability:

Highly regarded in off-road communities for its compact size, lightweight construction, and excellent articulation, often winning 'best in class' in various grassroots off-road events and comparisons.

Ratings

Reliability Perception:

Generally perceived as a reliable vehicle with a simple mechanical design, though parts availability and corrosion can be factors in older examples.