Suzuki Samurai & Sidekick Geo Tracker Complete Workshop Service Repair Manual 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996

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🏷️ Basic Information Identification Make: Suzuki, Geo Model: Samurai, Sidekick, Tracker Codes Chassis Codes: SJ410, SJ413 (Samurai), FT/ET (Sidekick/Tracker) 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, Suzuki/Geo vehicle owners seeking to perform their own maintenance and repairs Competitive Analysis Value Proposition: Cost savings by enabling owners to perform DIY repairs, comprehensive coverage for multiple model years and variants, detailed step-by-step instructions with illustrations Key Features Features: Step-by-step instructions, clear pictures/illustrations, troubleshooting guides, wiring diagrams, torque specifications, fluid capacities, maintenance schedules 📋 Manual Details Coverage Applicable Years: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 Models Covered: All Models, Engines, Trim Levels, and Transmission Types Format Manual Type: Complete Workshop Service Repair Manual Format Type: Downloadable Digital File (PDF) Language Language: English 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, clutch, manual transmission, automatic transmission, transfer case, drive axles Chassis: Suspension (front and rear), steering system, braking system (front and rear), wheels and tires Electrical: Battery, charging system, starting system, lighting, instrumentation, engine control system (ECM/ECU), body electrical systems, wiring diagrams Body: Body structure, exterior trim, interior trim, doors, windows, seats, HVAC (heating, ventilation, and air conditioning) Procedures Included Maintenance: Regular maintenance schedules, fluid changes, filter replacements, lubrication, inspections Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings Repair: Component removal and installation, overhaul procedures, adjustments, component repair Engine Mechanical Procedures: Engine assembly/disassembly, piston and ring replacement, bearing inspection, cylinder head servicing, valve timing, crankshaft and camshaft installation, oil pump replacement. Suspension Steering Procedures: Front and rear suspension component replacement (shocks, struts, springs, bushings), steering gear box overhaul, power steering pump replacement, tie rod and ball joint service. Brake System Procedures: Brake pad and shoe replacement, rotor and drum resurfacing/replacement, caliper and wheel cylinder rebuilding, brake line inspection and replacement, parking brake adjustment. Electrical System Procedures: Wiring harness troubleshooting, component testing (alternator, starter, ignition coil, sensors), lighting system diagnostics, fuse and relay identification and replacement, ECU diagnostics. Body And Interior Procedures: Door panel removal, window regulator replacement, seat removal and installation, HVAC blower motor replacement, dashboard disassembly for access to components, exterior trim repair. Technical Depth Depth: Comprehensive; covers basic maintenance to full engine and transmission rebuilds, detailed diagnostic procedures Diagnostic Charts: Detailed diagnostic flowcharts for troubleshooting common drivability, electrical, and mechanical issues. Torque Specifications: Comprehensive list of all critical torque values for fasteners across all systems. Wiring Diagrams: Complete, system-specific wiring diagrams for engine management, body electrical, lighting, and accessories. 📊 Manual Specifications File Details File Format: PDF (Portable Document Format) Accessibility: Printable (single page, chapter, or full document), viewable on PC, Mac, tablets, and smartphones Software Requirement: Adobe Reader (free download) Quality Page Count: Estimated 2000+ pages (typical for comprehensive workshop manuals of this era and scope) Print Quality: High Quality (implied by product description, likely containing clear diagrams and text) Binding Type Binding Type: N/A (Downloadable, no physical binding) Paper Type Paper Type: N/A (Downloadable, no physical paper) ⚙️ Engine Specifications Primary Engine Samurai Engine Code Samurai: G13A (1.3L), G13B (1.3L DOHC) for later Samurai models, F10A (1.0L) for earlier SJ410 Displacement Samurai: 1.0L (970cc), 1.3L (1298cc) Horsepower Samurai: Approx. 60-65 hp (1.3L carb), Approx. 70-75 hp (1.3L FI, DOHC) Torque Samurai: Approx. 70-75 lb-ft (1.3L carb), Approx. 75-80 lb-ft (1.3L FI, DOHC) Primary Engine Sidekick Tracker Engine Code Sidekick Tracker: G16A (1.6L SOHC), G16B (1.6L DOHC) Displacement Sidekick Tracker: 1.6L (1590cc) Horsepower Sidekick Tracker: Approx. 70-75 hp (1.6L SOHC), Approx. 95-100 hp (1.6L DOHC) Torque Sidekick Tracker: Approx. 80-85 lb-ft (1.6L SOHC), Approx. 95-100 lb-ft (1.6L DOHC) Fuel System Fuel Delivery Samurai: Carbureted (Hitachi/Mikuni) for early 1.3L, Fuel Injection (Multi-point) for later 1.3L and 1.6L models Fuel Delivery Sidekick Tracker: Fuel Injection (Multi-point) Performance Compression Ratio Samurai: Approx. 8.4:1 (1.3L Carb), 9.5:1 (1.3L FI) Compression Ratio Sidekick Tracker: 9.5:1 (1.6L DOHC) 🔧 Transmission Samurai Standard Transmission Samurai: 5-speed Manual (various gear ratios depending on model/transfer case) Optional Transmission Samurai: 3-speed Automatic (less common, typically on export models or later Sidekick/Tracker equivalents) Transfer Case Samurai: 2-speed Part-time 4WD with Neutral position (e.g., 1.3L 4WD, 1.0L 4WD) Sidekick Tracker Standard Transmission Sidekick Tracker: 5-speed Manual Optional Transmission Sidekick Tracker: 4-speed Automatic Drivetrain Sidekick Tracker: 4WD, optional 2WD (on some Tracker trims) Transfer Case Sidekick Tracker: 2-speed 4WD with Neutral position (on 4WD models) 📐 Dimensions Samurai Wheelbase Samurai: 80.0 inches (2030 mm) Length Samurai: Approx. 142.5 inches (3620 mm) (soft top), Approx. 152.6 inches (3875 mm) (hardtop) Width Samurai: Approx. 61.4 inches (1560 mm) Height Samurai: Approx. 65.0 inches (1650 mm) (hardtop) Curb Weight Samurai: Approx. 1900-2100 lbs (860-950 kg) Sidekick Tracker Wheelbase Sidekick Tracker: 89.4 inches (2270 mm) (short wheelbase), 97.4 inches (2475 mm) (long wheelbase on later models) Length Sidekick Tracker: Approx. 158.7 inches (4030 mm) (short...

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Tags: 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 Car Cars Geo Tracker Samurai Sidekick Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki, Geo

Model:

Samurai, Sidekick, Tracker

Codes

Chassis Codes:

SJ410, SJ413 (Samurai), FT/ET (Sidekick/Tracker)

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts, independent repair shops, Suzuki/Geo vehicle owners seeking to perform their own maintenance and repairs

Competitive Analysis

Value Proposition:

Cost savings by enabling owners to perform DIY repairs, comprehensive coverage for multiple model years and variants, detailed step-by-step instructions with illustrations

Key Features

Features:

Step-by-step instructions, clear pictures/illustrations, troubleshooting guides, wiring diagrams, torque specifications, fluid capacities, maintenance schedules

📋 Manual Details

Coverage

Applicable Years:

1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

Models Covered:

All Models, Engines, Trim Levels, and Transmission Types

Format

Manual Type:

Complete Workshop Service Repair Manual

Format Type:

Downloadable Digital File (PDF)

Language

Language:

English

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, clutch, manual transmission, automatic transmission, transfer case, drive axles

Chassis:

Suspension (front and rear), steering system, braking system (front and rear), wheels and tires

Electrical:

Battery, charging system, starting system, lighting, instrumentation, engine control system (ECM/ECU), body electrical systems, wiring diagrams

Body:

Body structure, exterior trim, interior trim, doors, windows, seats, HVAC (heating, ventilation, and air conditioning)

Procedures Included

Maintenance:

Regular maintenance schedules, fluid changes, filter replacements, lubrication, inspections

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings

Repair:

Component removal and installation, overhaul procedures, adjustments, component repair

Engine Mechanical Procedures:

Engine assembly/disassembly, piston and ring replacement, bearing inspection, cylinder head servicing, valve timing, crankshaft and camshaft installation, oil pump replacement.

Suspension Steering Procedures:

Front and rear suspension component replacement (shocks, struts, springs, bushings), steering gear box overhaul, power steering pump replacement, tie rod and ball joint service.

Brake System Procedures:

Brake pad and shoe replacement, rotor and drum resurfacing/replacement, caliper and wheel cylinder rebuilding, brake line inspection and replacement, parking brake adjustment.

Electrical System Procedures:

Wiring harness troubleshooting, component testing (alternator, starter, ignition coil, sensors), lighting system diagnostics, fuse and relay identification and replacement, ECU diagnostics.

Body And Interior Procedures:

Door panel removal, window regulator replacement, seat removal and installation, HVAC blower motor replacement, dashboard disassembly for access to components, exterior trim repair.

Technical Depth

Depth:

Comprehensive; covers basic maintenance to full engine and transmission rebuilds, detailed diagnostic procedures

Diagnostic Charts:

Detailed diagnostic flowcharts for troubleshooting common drivability, electrical, and mechanical issues.

Torque Specifications:

Comprehensive list of all critical torque values for fasteners across all systems.

Wiring Diagrams:

Complete, system-specific wiring diagrams for engine management, body electrical, lighting, and accessories.

📊 Manual Specifications

File Details

File Format:

PDF (Portable Document Format)

Accessibility:

Printable (single page, chapter, or full document), viewable on PC, Mac, tablets, and smartphones

Software Requirement:

Adobe Reader (free download)

Quality

Page Count:

Estimated 2000+ pages (typical for comprehensive workshop manuals of this era and scope)

Print Quality:

High Quality (implied by product description, likely containing clear diagrams and text)

Binding Type

Binding Type:

N/A (Downloadable, no physical binding)

Paper Type

Paper Type:

N/A (Downloadable, no physical paper)

⚙️ Engine Specifications

Primary Engine Samurai

Engine Code Samurai:

G13A (1.3L), G13B (1.3L DOHC) for later Samurai models, F10A (1.0L) for earlier SJ410

Displacement Samurai:

1.0L (970cc), 1.3L (1298cc)

Horsepower Samurai:

Approx. 60-65 hp (1.3L carb), Approx. 70-75 hp (1.3L FI, DOHC)

Torque Samurai:

Approx. 70-75 lb-ft (1.3L carb), Approx. 75-80 lb-ft (1.3L FI, DOHC)

Primary Engine Sidekick Tracker

Engine Code Sidekick Tracker:

G16A (1.6L SOHC), G16B (1.6L DOHC)

Displacement Sidekick Tracker:

1.6L (1590cc)

Horsepower Sidekick Tracker:

Approx. 70-75 hp (1.6L SOHC), Approx. 95-100 hp (1.6L DOHC)

Torque Sidekick Tracker:

Approx. 80-85 lb-ft (1.6L SOHC), Approx. 95-100 lb-ft (1.6L DOHC)

Fuel System

Fuel Delivery Samurai:

Carbureted (Hitachi/Mikuni) for early 1.3L, Fuel Injection (Multi-point) for later 1.3L and 1.6L models

Fuel Delivery Sidekick Tracker:

Fuel Injection (Multi-point)

Performance

Compression Ratio Samurai:

Approx. 8.4:1 (1.3L Carb), 9.5:1 (1.3L FI)

Compression Ratio Sidekick Tracker:

9.5:1 (1.6L DOHC)

🔧 Transmission

Samurai

Standard Transmission Samurai:

5-speed Manual (various gear ratios depending on model/transfer case)

Optional Transmission Samurai:

3-speed Automatic (less common, typically on export models or later Sidekick/Tracker equivalents)

Transfer Case Samurai:

2-speed Part-time 4WD with Neutral position (e.g., 1.3L 4WD, 1.0L 4WD)

Sidekick Tracker

Standard Transmission Sidekick Tracker:

5-speed Manual

Optional Transmission Sidekick Tracker:

4-speed Automatic

Drivetrain Sidekick Tracker:

4WD, optional 2WD (on some Tracker trims)

Transfer Case Sidekick Tracker:

2-speed 4WD with Neutral position (on 4WD models)

📐 Dimensions

Samurai

Wheelbase Samurai:

80.0 inches (2030 mm)

Length Samurai:

Approx. 142.5 inches (3620 mm) (soft top), Approx. 152.6 inches (3875 mm) (hardtop)

Width Samurai:

Approx. 61.4 inches (1560 mm)

Height Samurai:

Approx. 65.0 inches (1650 mm) (hardtop)

Curb Weight Samurai:

Approx. 1900-2100 lbs (860-950 kg)

Sidekick Tracker

Wheelbase Sidekick Tracker:

89.4 inches (2270 mm) (short wheelbase), 97.4 inches (2475 mm) (long wheelbase on later models)

Length Sidekick Tracker:

Approx. 158.7 inches (4030 mm) (short wheelbase convertible)

Width Sidekick Tracker:

Approx. 66.1 inches (1680 mm)

Curb Weight Sidekick Tracker:

Approx. 2400-2700 lbs (1090-1225 kg)

Wheel Tire

Wheel Bolt Pattern All:

5x139.7 mm (4.5 inch PCD)

Tire Size Samurai:

Commonly 205/75R15, 215/75R15, 235/75R15 (off-road variants often use larger sizes)

Tire Size Sidekick Tracker:

Commonly 205/75R15, 215/70R16

🛡️ Safety Features

Ratings

Crash Test Ratings:

NHTSA ratings varied by year and model, often considered less robust by modern standards due to their lightweight, body-on-frame construction. Specific ratings should be verified for individual model years.

Active Features

Active Safety Features:

Four-wheel drive system for enhanced traction

Passive Features

Passive Safety Features:

Seat belts (3-point front, 2-point rear), roll bar integrated into the body structure (Samurai), basic body structure

💡 Technology Features

Infotainment

Infotainment Systems:

Basic AM/FM radio, cassette player, optional CD player (later models), analog gauges for speedometer, tachometer (sometimes), fuel, temperature, oil pressure.

Driver Assistance

Driver Assistance Features:

Limited to basic safety features. ABS was an option on some Sidekick/Tracker models towards the end of the covered period.

Connectivity

Connectivity Features:

No integrated smartphone connectivity or advanced electronic features typical of modern vehicles.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, whichever comes first (refer to manual for exact specifications based on engine type and driving conditions).

Air Filter Replacement Interval:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plug Replacement Interval:

Every 30,000-60,000 miles (48,000-96,000 km), depending on spark plug type (copper vs. platinum).

Fluid Specifications

Engine Oil Type Samurai:

API SG, SF or CC, SJ, SH rated SAE 10W-30 or 10W-40 (check manual for temperature specific recommendations)

Engine Oil Type Sidekick Tracker:

API SG, SF or CC, SJ, SH rated SAE 5W-30 or 10W-30 (check manual for temperature specific recommendations)

Coolant Type All:

Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Use a recognized coolant meeting the vehicle's specifications (e.g., Japanese coolant standards).

Transmission Fluid Type Manual:

GL-4 Gear Oil, SAE 75W-90 or 80W-90

Transmission Fluid Type Automatic:

Dexron-III (or equivalent) Automatic Transmission Fluid (ATF)

Transfer Case Fluid Type:

GL-4 Gear Oil, SAE 75W-90 or 80W-90

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Known Issues

Samurai Common Issues:

Rust (frame, body panels), clutch wear, transmission synchromesh issues, carburetor tuning, differential pinion seal leaks, exhaust manifold cracks, ignition system component failures.

Sidekick Tracker Common Issues:

Head gasket failure (especially on early 1.6L engines), timing belt replacement (critical maintenance), rear main seal leaks, catalytic converter issues, power steering pump leaks, window regulator failure, ABS sensor issues (if equipped).

📚 Vehicle History

Brand Heritage

Suzuki Offroad Legacy:

Suzuki's long history of producing rugged, compact off-road vehicles, tracing roots back to the Jimny series.

Model Evolution

Samurai Evolution:

Successor to the Suzuki SJ series, known for its compact size, lightweight, and capable off-road performance. Marketed as a budget-friendly 4x4. Faced controversy regarding rollover propensity, leading to some safety upgrades and marketing changes.

Sidekick Tracker Evolution:

Jointly developed with General Motors (as Geo Tracker, later Chevrolet Tracker), offered a more car-like ride and amenities compared to the Samurai, with a unibody construction for a softer ride and better on-road manners, while still retaining 4WD capability. Available in convertible and hardtop variants.

Production

Samurai Production Period:

Global production ran longer, but US market production for Samurai ended in 1995. The models covered by this manual (1986-1995) represent its primary North American tenure.

Sidekick Tracker Production Period:

Covered range for Sidekick/Tracker is 1989-1998 (Suzuki Sidekick) and 1989-1997 (Geo/Chevrolet Tracker). Manual covers up to 1996.