🏷️ Basic Information

Make:

Suzuki

Model:

SJ Samurai

Model Generations Covered:

SJ Series (all generations of SJ Samurai)

Production Eras Covered:

1980s - 1990s (primarily, with some early model variations)

Chassis Codes:

SJ410, SJ413, JA11, JA12, JA22

Engine Codes:

F10A (970cc), F8A (797cc), G13A (1.3L SOHC), G13B (1.3L SOHC VVT), G16A (1.6L SOHC), G16B (1.6L DOHC VVT)

👋 Introduction

Vehicle Market Segment:

Compact SUV / Off-road vehicle.

Key Competitors Era:

Jeep Wrangler, Toyota Land Cruiser (FJ40/FJ60), Lada Niva, Ford Bronco II.

Vehicle Key Attributes:

Compact size, robust 4WD system, high ground clearance, simplicity, affordability, excellent off-road capability.

Manual Value Proposition:

Empowers owners and technicians with detailed knowledge for reliable maintenance and repair of a cult classic off-road vehicle.

📋 Manual Details

Manual Coverage Scope:

Comprehensive service and repair procedures for the entire vehicle.

Estimated Page Count:

1000+

Manual Format Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Download Format:

PDF Download

📖 Manual Coverage

Engine Systems:

Engine mechanicals (disassembly, assembly, overhaul), cooling system, lubrication system, fuel system (carbureted and fuel injected), ignition system, emissions control systems.

Drivetrain Systems:

Clutch system, manual transmission (transfer case, 4WD system), differentials, axle shafts, driveshafts.

Suspension Steering Brakes:

Front and rear suspension (leaf spring, coil spring), steering system (steering box, linkage), brake system (front disc, rear drum), parking brake.

Electrical Systems:

Battery, charging system (alternator, starter), lighting system, wiring diagrams, fuses, relays, instrumentation, engine control unit (ECU) diagnostics (for fuel-injected models).

Body Chassis:

Body panels, doors, interior trim, seats, chassis frame, body mounts, exhaust system.

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt adjustments, battery maintenance, general inspection and cleaning.

Repair Procedures:

Engine rebuilding, transmission overhaul, differential repair, brake component replacement, suspension component replacement, steering system repair, electrical component troubleshooting and replacement.

Troubleshooting Diagnostics:

Step-by-step diagnostic charts for common drivability issues, electrical faults, and mechanical problems. Identification of symptoms and probable causes.

Depth Of Information:

Detailed disassembly and reassembly procedures, torque specifications, clearance measurements, timing adjustments, diagnostic procedures, wiring diagrams, component identification.

📊 Manual Specifications

Digital File Format:

PDF

Scanned Image Quality:

High-resolution scans, often with searchable text (OCR).

Digital Binding Analogy:

N/A (Digital download)

Digital Paper Analogy:

N/A (Digital download)

⚙️ Engine Specifications

Most Common Engine Variant:

1.3L G13A SOHC I4 (Carbureted/Fuel Injection)

Typical Horsepower 1.3L:

60-70 HP (varies by year/market)

Typical Torque 1.3L:

70-75 lb-ft (varies by year/market)

Fuel Delivery 1.3L Early:

Carburetor (e.g., Mikuni 2-barrel)

Fuel Delivery 1.3L Late:

Multi-point Fuel Injection (MPI) for later models (e.g., G13B)

Engine Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

Cooling System Type:

Pressurized Liquid Cooling

Oil Capacity W Filter:

Approx. 3.5 Liters (3.7 Quarts)

🔧 Transmission

Standard Transmission Type:

5-Speed Manual

Optional Transmission Type:

3-Speed Automatic (less common)

Transfer Case Type:

2-Speed Transfer Case with High/Low Range and Neutral

Drive System:

Part-time 4WD (selectable 2WD/4WD High/4WD Low)

Manual Transmission Fluid Type:

API GL-4 Hypoid Gear Oil (e.g., 75W-90 or 80W-90)

Transfer Case Fluid Type:

API GL-4 Hypoid Gear Oil (e.g., 75W-90 or 80W-90)

Differential Fluid Type:

API GL-5 Hypoid Gear Oil (e.g., 80W-90)

📐 Dimensions

Wheelbase Typical:

2030 mm (80 inches)

Overall Length:

3,565 mm (140.4 inches)

Overall Width:

1,505 mm (59.3 inches)

Overall Height:

1,670 mm (65.7 inches) (Hardtop)

Curb Weight Typical:

960 kg (2,116 lbs)

Gross Vehicle Weight Rating Gvwr:

Approx. 1400-1500 kg (3086-3307 lbs)

Cargo Volume Rear Seats Folded:

Variable, but compact

🛡️ Safety Features

Crash Test Ratings Era:

Limited official ratings due to era and vehicle type; known for rollovers in certain conditions.

Braking System:

Front disc brakes, rear drum brakes. Power assist (optional/later models).

Seatbelts:

Standard lap belts, front shoulder belts (later models).

Rollover Protection:

Integral roll cage in hardtop models, roll bar in soft-top models.

💡 Technology Features

Infotainment Features Era:

Basic AM/FM radio, optional cassette player, analog gauges.

Driver Assistance Systems:

None standard; basic power steering (optional/later models).

Connectivity Features:

N/A (pre-digital era connectivity).

🔧 Maintenance

Engine Oil Change Interval:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months.

Transmission Fluid Change Interval:

Every 30,000-50,000 miles (50,000-80,000 km).

Differential Fluid Change Interval:

Every 30,000-50,000 miles (50,000-80,000 km).

Engine Oil Specification Typical:

API SG or SH, SAE 10W-30 or 10W-40 (consult manual for specific engine/climate recommendations)

Coolant Specification:

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

Brake Fluid Specification:

DOT 3 or DOT 4.

Common Wear Item Corrosion:

Frame rust and body corrosion, particularly in areas exposed to salt.

Common Engine Issue Carburetor:

Carburetor issues (gumming, vacuum leaks) on older models.

Common Drivetrain Issue:

Transfer case chain stretch or worn synchros in manual transmissions.

Common Suspension Issue:

Worn leaf springs, U-joints, and bushings due to off-road use.

Common Electrical Issue:

Fraying wiring harnesses, aging electrical connectors, starter motor issues.

📚 Vehicle History

Suzuki Offroad Legacy:

Suzuki has a long history of producing capable and compact off-road vehicles, starting with models like the LJ series, leading to the SJ series.

Sj Series Development:

Evolved from the LJ series, with significant updates in engine size (SJ410 to SJ413) and chassis design for improved performance and market appeal.

Global Production Locations:

Japan (main), also manufactured or assembled in various other countries under license (e.g., Spain, India, Pakistan, Brazil).

Discontinuation Region Specific:

Discontinued in many markets by the late 1990s/early 2000s, but continued in some (e.g., India as Maruti Gypsy).

🏆 Awards & Recognition

Vehicle Cult Status:

Recognized as a highly capable and iconic off-road vehicle with a strong enthusiast following.

Offroad Capability Rating:

Excellent, often surpassing larger and more expensive SUVs in extreme conditions due to its light weight and articulation.

Manual Certification Analogy:

N/A (Industry-standard factory documentation)