Suzuki Samurai SJ 410 Manual, 1987 edition - Authorized Service & Repair Guide for Classic SUV

1987 Suzuki Samurai SJ 410 Service Manual

• Built for owners and professional workshops servicing the 1987 Suzuki Samurai and SJ 410, focusing on the 4-cylinder gasoline engine and associated drivetrain
• Official OEM publication P/N 99500-83310-33E, issued 1987
• Documents engine disassembly, cylinder head inspection, valve seat repair, and bottom-end assembly with 100+ technical drawings and cross-reference tables
• Downloads to your account within seconds of checkout
• Re-download the file any time, no expiration
• Indexed PDF search covers every chapter and appendix
• Laid out for standard letter and A4 printing
• This 482-page 1987 first edition is the primary factory reference for the 410-series body and 1.3L-class powertrain build

Engine and Chassis Walkthrough

This 1987 Suzuki Samurai SJ 410 service manual provides technical data for major component disassembly and reassembly. The document details the S.O.H.C. engine internal specifications, including camshaft inspection, piston-to-cylinder clearance, and valve lash adjustments. Further chapters define the fuel system components, including the carburetor, fuel pump, and air cleaner maintenance. The transmission and transfer case documentation provides oil specifications and gear shifting control diagnostics. Suspension, steering, and braking system maintenance is also organized by system component for efficient review.

Specification Highlights

Technical data is provided for critical assemblies throughout the vehicle. The engine lubrication system documents relief valve pressure settings of 3.0 kg/cm² (42.7 psi, 300 kPa). Connecting rod bearing clearance is specified at 0.10–0.20 mm, while piston ring end gaps are documented for top, 2nd, and oil rings. Tightening torque for the oil pan bolts is listed at 9–12 Nm, and cylinder head bolt torque is defined within the engine reassembly data. Electrical specifications for the starting motor and charging system include coil resistance and regulator troubleshooting. Valve clearance for the intake is listed at 0.13–0.17 mm in the cylinder head specification table. Coolant system capacity for the 1987 Suzuki Samurai is documented at 4.8 liters. The differential drive pinion backlash is specified in the drivetrain data section for repair reference. An official 482-page Suzuki OEM workshop manual covering the 1987 Suzuki Samurai and SJ 410, documenting engine, chassis, electrical, and fuel-injection specifications for the J4-series build.