1986-1996 Suzuki Samurai & Sidekick GEO Track Workshop Service Repair Manual

Regular price: $141.00
Sale price: $141.00
Regular price
Unit price: per

🏷️ Basic Information Identification Make: Suzuki / Geo Model: Samurai / Sidekick / Tracker Product Name: 1986-1996 Suzuki Samurai & Sidekick GEO Track Workshop Service Repair Manual Generation Samurai Generation: SJ410/SJ413 (First Generation) Sidekick Tracker Generation: First Generation (1989-1998) Codes Vin Code Samurai: JS3SJ (typically for SJ413 models) Vin Code Sidekick Tracker: 1G5... (for Geo Tracker models) 👋 Introduction Market Position Positioning: A critical resource for owners and independent repair shops specializing in the Suzuki Samurai, Geo Sidekick, and Geo Tracker, known for their off-road capability and relatively simple mechanicals. Competitive Analysis Analogy: Comparable to factory service manuals (FSMs) from manufacturers like Chilton or Haynes, but often more detailed and comprehensive as it aims to replicate technician-level information. Key Features Features: Step-by-step instructions, extensive illustrations and diagrams, detailed specifications, troubleshooting guides, and wiring schematics. 📋 Manual Details Coverage Areas Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 Page Count Estimated Page Count: Likely 1000+ pages, typical for comprehensive workshop manuals of this era. Manual Type Type: Workshop Service and Repair Manual Type Description: This is a workshop manual, designed for repair and maintenance, not an owner's manual or parts catalog. Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, rebuilding, performance, timing belt replacement, firing orders, component diagnostics. Engine Electrical: Wiring diagrams, ignition system, starting and charging systems, engine control units (ECU). Transmission: Manual and automatic transmission removal, installation, and in-car servicing. Drivetrain: Driveshaft, U-joints, CV-joints, differentials, 4WD system servicing. Brakes: Brake servicing, hydraulic systems, disc and drum brake procedures, parking brake. Suspension: Front and rear suspension, shock absorbers, springs, bushings, steering components. Steering: Steering gear, power steering system (if equipped), alignment procedures and specifications. Body: Body panel repairs, door mechanisms, glass replacement, sunroof servicing. HVAC: Air conditioning system servicing, refrigerant capacities, heater core, climate control. Electrical Components: Lighting systems, interior electronics, dashboard instruments, power accessories. Diagnostic Systems: Trouble codes, computer diagnostic trouble tree charts, troubleshooting and diagnostics. Frame Chassis: Frame inspection, rust repair procedures (critical for Samurai), body mounting, suspension attachment points. Fuel System Repair: Carburetor (rebuilding, tuning, adjustment) and fuel injection system diagnostics and repair, including fuel pump, injectors, and pressure regulators. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, belt inspections, scheduled maintenance. Major Repairs: Engine rebuilding, transmission overhauls, suspension component replacement, brake system overhauls. Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues. Restoration: Detailed procedures for refurbishing and restoring various vehicle components. Customization: While not explicitly stated, comprehensive manuals often provide insights useful for modification. Alignment Procedures: Detailed specifications and procedures for front-end alignment, including camber, caster, and toe settings. Technical Depth Depth: Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds). Target Audience: Professional technicians, experienced DIY mechanics, and owners seeking in-depth knowledge. Diagnostic Tools Needed: Basic hand tools, torque wrenches, multimeter, fuel pressure gauge, vacuum gauge, timing light (for carbureted models). OBD-I scan tools for later models. Wiring Diagrams Detail: Comprehensive wiring schematics covering engine, chassis, lighting, and accessories. Essential for electrical troubleshooting. 📊 Manual Specifications File Format Format Details: Digital PDF, likely searchable and printable. Quality indicated as '100 percents COMPLETE; no MISSING/CORRUPT pages/sections'. Print Quality Quality Description: The product description highlights 'pictures and easy to follow directions', 'hundreds of illustrations', 'diagrams', and 'wiring schematic', suggesting good visual content. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Samurai Engine 1986-1988: 1.3L (1324cc) G13A SOHC I4 (8 valves). Carbureted. Samurai Engine 1989-1995: 1.3L (1324cc) G13BA SOHC I4 (8 valves). Fuel Injected (MPI) for later models in some markets. Sidekick Tracker Engine Early: 1.6L (1590cc) G16A SOHC I4 (8 valves). Carbureted or early Fuel Injection. Sidekick Tracker Engine Later: 1.6L (1590cc) G16B DOHC I4 (16 valves). Multi-Point Fuel Injection (MPI). Also 1.8L J18A DOHC I4 (16 valves) for later Sidekicks. Performance Samurai 1.3L Power: Approx. 64-70 hp @ 5500 rpm (varies by year and market) Samurai 1.3L Torque: Approx. 72-76 lb-ft @ 3000-3500 rpm (varies by year and market) Sidekick Tracker 1.6L Mpi Power: Approx. 95-102 hp @ 5500-6000 rpm Sidekick Tracker 1.6L Mpi Torque: Approx. 95-103 lb-ft @ 3500-4000 rpm Fuel System Samurai Fuel System: Carbureted (Hitachi/Keihin models typically) for most 1986-1991 models. Fuel Injection (MPI) for later Samurai models in certain markets. Sidekick Tracker Fuel System: Early models may be carbureted. Later models predominantly use Multi-Point Fuel Injection (MPI). 🔧 Transmission Standard Samurai Transmission: 4-speed manual (early), 5-speed manual (common from late 80s onward). Sidekick Tracker Transmission: 5-speed manual. Optional Samurai Transmission Optional: 3-speed automatic (less common). Sidekick Tracker Transmission Optional: 4-speed automatic. Features 4Wd System: Part-time 4WD with selectable 2WD/4WD engagement via a manual transfer case lever. Hi/Lo range gearing typically included. 📐 Dimensions Exterior Samurai Wheelbase: Approx. 80.3 inches (2040 mm)...

16 people are viewing this right now

Type: Car

Vendor:

Sku: 294912

Collections: ALL Suzuki

Availability: In stock

Tags: 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 Car GEO Track Misc Motorcycles Samurai Sidekick Suzuki

Product variants

Description

🏷️ Basic Information

Identification

Make:

Suzuki / Geo

Model:

Samurai / Sidekick / Tracker

Product Name:

1986-1996 Suzuki Samurai & Sidekick GEO Track Workshop Service Repair Manual

Generation

Samurai Generation:

SJ410/SJ413 (First Generation)

Sidekick Tracker Generation:

First Generation (1989-1998)

Codes

Vin Code Samurai:

JS3SJ (typically for SJ413 models)

Vin Code Sidekick Tracker:

1G5... (for Geo Tracker models)

👋 Introduction

Market Position

Positioning:

A critical resource for owners and independent repair shops specializing in the Suzuki Samurai, Geo Sidekick, and Geo Tracker, known for their off-road capability and relatively simple mechanicals.

Competitive Analysis

Analogy:

Comparable to factory service manuals (FSMs) from manufacturers like Chilton or Haynes, but often more detailed and comprehensive as it aims to replicate technician-level information.

Key Features

Features:

Step-by-step instructions, extensive illustrations and diagrams, detailed specifications, troubleshooting guides, and wiring schematics.

📋 Manual Details

Coverage Areas

Years Covered:

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

Page Count

Estimated Page Count:

Likely 1000+ pages, typical for comprehensive workshop manuals of this era.

Manual Type

Type:

Workshop Service and Repair Manual

Type Description:

This is a workshop manual, designed for repair and maintenance, not an owner's manual or parts catalog.

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, rebuilding, performance, timing belt replacement, firing orders, component diagnostics.

Engine Electrical:

Wiring diagrams, ignition system, starting and charging systems, engine control units (ECU).

Transmission:

Manual and automatic transmission removal, installation, and in-car servicing.

Drivetrain:

Driveshaft, U-joints, CV-joints, differentials, 4WD system servicing.

Brakes:

Brake servicing, hydraulic systems, disc and drum brake procedures, parking brake.

Suspension:

Front and rear suspension, shock absorbers, springs, bushings, steering components.

Steering:

Steering gear, power steering system (if equipped), alignment procedures and specifications.

Body:

Body panel repairs, door mechanisms, glass replacement, sunroof servicing.

HVAC:

Air conditioning system servicing, refrigerant capacities, heater core, climate control.

Electrical Components:

Lighting systems, interior electronics, dashboard instruments, power accessories.

Diagnostic Systems:

Trouble codes, computer diagnostic trouble tree charts, troubleshooting and diagnostics.

Frame Chassis:

Frame inspection, rust repair procedures (critical for Samurai), body mounting, suspension attachment points.

Fuel System Repair:

Carburetor (rebuilding, tuning, adjustment) and fuel injection system diagnostics and repair, including fuel pump, injectors, and pressure regulators.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, belt inspections, scheduled maintenance.

Major Repairs:

Engine rebuilding, transmission overhauls, suspension component replacement, brake system overhauls.

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues.

Restoration:

Detailed procedures for refurbishing and restoring various vehicle components.

Customization:

While not explicitly stated, comprehensive manuals often provide insights useful for modification.

Alignment Procedures:

Detailed specifications and procedures for front-end alignment, including camber, caster, and toe settings.

Technical Depth

Depth:

Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds).

Target Audience:

Professional technicians, experienced DIY mechanics, and owners seeking in-depth knowledge.

Diagnostic Tools Needed:

Basic hand tools, torque wrenches, multimeter, fuel pressure gauge, vacuum gauge, timing light (for carbureted models). OBD-I scan tools for later models.

Wiring Diagrams Detail:

Comprehensive wiring schematics covering engine, chassis, lighting, and accessories. Essential for electrical troubleshooting.

📊 Manual Specifications

File Format

Format Details:

Digital PDF, likely searchable and printable. Quality indicated as '100 percents COMPLETE; no MISSING/CORRUPT pages/sections'.

Print Quality

Quality Description:

The product description highlights 'pictures and easy to follow directions', 'hundreds of illustrations', 'diagrams', and 'wiring schematic', suggesting good visual content.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Samurai Engine 1986-1988:

1.3L (1324cc) G13A SOHC I4 (8 valves). Carbureted.

Samurai Engine 1989-1995:

1.3L (1324cc) G13BA SOHC I4 (8 valves). Fuel Injected (MPI) for later models in some markets.

Sidekick Tracker Engine Early:

1.6L (1590cc) G16A SOHC I4 (8 valves). Carbureted or early Fuel Injection.

Sidekick Tracker Engine Later:

1.6L (1590cc) G16B DOHC I4 (16 valves). Multi-Point Fuel Injection (MPI). Also 1.8L J18A DOHC I4 (16 valves) for later Sidekicks.

Performance

Samurai 1.3L Power:

Approx. 64-70 hp @ 5500 rpm (varies by year and market)

Samurai 1.3L Torque:

Approx. 72-76 lb-ft @ 3000-3500 rpm (varies by year and market)

Sidekick Tracker 1.6L Mpi Power:

Approx. 95-102 hp @ 5500-6000 rpm

Sidekick Tracker 1.6L Mpi Torque:

Approx. 95-103 lb-ft @ 3500-4000 rpm

Fuel System

Samurai Fuel System:

Carbureted (Hitachi/Keihin models typically) for most 1986-1991 models. Fuel Injection (MPI) for later Samurai models in certain markets.

Sidekick Tracker Fuel System:

Early models may be carbureted. Later models predominantly use Multi-Point Fuel Injection (MPI).

🔧 Transmission

Standard

Samurai Transmission:

4-speed manual (early), 5-speed manual (common from late 80s onward).

Sidekick Tracker Transmission:

5-speed manual.

Optional

Samurai Transmission Optional:

3-speed automatic (less common).

Sidekick Tracker Transmission Optional:

4-speed automatic.

Features

4Wd System:

Part-time 4WD with selectable 2WD/4WD engagement via a manual transfer case lever. Hi/Lo range gearing typically included.

📐 Dimensions

Exterior

Samurai Wheelbase:

Approx. 80.3 inches (2040 mm)

Samurai Length:

Approx. 143 inches (3630 mm) for soft top.

Samurai Width:

Approx. 59.8 inches (1520 mm).

Samurai Height:

Approx. 63 inches (1600 mm) for soft top.

Sidekick Tracker Wheelbase:

Approx. 86.6 inches (2200 mm)

Sidekick Tracker Length:

Approx. 157.3 inches (4000 mm)

Sidekick Tracker Width:

Approx. 66.1 inches (1680 mm)

Sidekick Tracker Height:

Approx. 64.6 inches (1640 mm)

Weights

Samurai Curb Weight:

Approx. 2000-2200 lbs (900-1000 kg)

Sidekick Tracker Curb Weight:

Approx. 2400-2600 lbs (1100-1200 kg)

🛡️ Safety Features

Ratings

Samurai Safety Era:

Designed and sold in an era with less stringent safety regulations compared to modern vehicles. Rollover potential due to narrow track and high center of gravity.

Sidekick Tracker Safety Era:

Improved safety features compared to Samurai, with wider track, but still considered basic by modern standards.

Active Features

Active Features Standard:

Four-wheel drive system for improved traction.

Passive Features

Passive Features Standard:

Basic seat belts, limited chassis crumple zones, roll bar in some configurations.

💡 Technology Features

Infotainment

Infotainment Era:

Basic for the time. Primarily AM/FM radio, cassette player. Manual windows and locks were standard on many trims. Optional power windows/locks and A/C.

Driver Assistance

Driver Assistance Features:

None by modern definition. ABS was optional or not available on early models. 4WD system is the primary 'assistance' feature.

Connectivity

Connectivity Features:

None. No provisions for Bluetooth, USB, or other modern connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions. Consult manual for exact recommendation.

Timing Belt Interval:

For G16A/G16B and G13BA engines, typically around 60,000-90,000 miles (96,000-144,000 km). Critical to follow, as failure can cause severe engine damage.

Fluid Specifications

Engine Oil Specification:

API SG or higher, SAE 10W-30 or 10W-40 is common for most conditions. Check manual for precise viscosity and API rating.

Coolant Specification:

Ethylene glycol-based antifreeze. Typically a 50/50 mix with distilled water. Check manual for specific type (e.g., green conventional) and capacity.

Transmission Fluid Manual:

API GL-4 gear oil, SAE 75W-90 or 75W-85 is common for manual transmissions. Suzuki Genuine Gear Oil or equivalent.

Transmission Fluid Automatic:

Dexron-II or Dexron-III compatible ATF (Automatic Transmission Fluid). Check manual for specific fluid type and capacity.

Differential Fluid:

API GL-5 gear oil, SAE 80W-90 or 75W-90 is typical for front and rear differentials and the transfer case. Check manual for specifics.

Known Issues

Samurai Common Issues:

Rust (especially frame, body mounts, floor pans), clutch wear, overheating (due to small radiator capacity), carburetor tuning issues, driveshaft/U-joint wear, vacuum leaks.

Sidekick Tracker Common Issues:

Timing belt failure (if not replaced on schedule), head gasket issues, intake manifold leaks, rear main seal leaks, catalytic converter failure, rust.

📚 Vehicle History

Brand Heritage

Suzuki Heritage:

Suzuki has a long history of producing small, rugged, and affordable vehicles, particularly off-roaders like the Jimny (Kei car equivalent).

Model Evolution

Samurai Evolution:

Successor to the popular Suzuki SJ series (SJ410, SJ413). Known for its compact size, lightweight construction, and excellent off-road capability for its class.

Sidekick Tracker Evolution:

Developed in conjunction with General Motors. The Geo Tracker was a rebadged version of the Suzuki Vitara/Escudo. Introduced as a more comfortable and road-biased SUV compared to the Samurai.

Production

Samurai Production Timeline:

Global production from the early 1970s (as SJ series) to 2004 in some markets. The 1986-1996 period covers a significant era for its North American market presence.

Sidekick Tracker Production Timeline:

First generation ran from 1989 to 1998 globally. The Geo Tracker was sold in North America from 1989 to 2004 (with the Suzuki Vitara taking over after 1998).