1987 Suzuki Samurai Service Manual

The 1987 Suzuki Samurai is a compact 4WD off-road vehicle featuring a 1.3L 4-cylinder engine, 5-speed manual transmission, part-time 4WD system, ladder frame chassis, and rugged suspension. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for all major systems including engine, transmission, transfer case, brakes, electrical, and body components.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Service 4. Transmission & Drivetrain 5. Brake System 6. Electrical System 7. Suspension & Steering 8. Body & Interior 9. Troubleshooting Guide 10. Technical Data 11. Wiring Diagrams

Vehicle Specifications

Key specifications for the 1987 Suzuki Samurai including dimensions, capacities, and performance data.

Specification	Description
Engine	1.3L G13A 4-cylinder SOHC
Displacement	1324 cc
Horsepower	64 hp @ 6000 rpm
Torque	76 lb-ft @ 3500 rpm
Transmission	5-speed manual
Transfer Case	Part-time 4WD with 2H/4H/4L
Wheelbase	79.9 inches
Length	135.4 inches
Width	60.6 inches
Height	65.2 inches
Curb Weight	2095 lbs
Fuel Capacity	10.6 gallons

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

Oil Change: Every 3,000 miles or 3 months
Oil Filter: Replace with every oil change
Air Filter: Every 15,000 miles
Spark Plugs: Every 30,000 miles
Timing Belt: Every 60,000 miles
Coolant: Every 30,000 miles or 2 years
Brake Fluid: Every 30,000 miles or 2 years
Transfer Case Fluid: Every 30,000 miles
Differential Fluid: Every 30,000 miles

WARNING! Always use jack stands when working under vehicle. Ensure parking brake is engaged.

Engine Service

Detailed procedures for engine maintenance and repair.

Valve Adjustment: Set intake 0.006-0.008 in, exhaust 0.008-0.010 in (cold)
Ignition Timing: 8° BTDC at 850 rpm
Compression: 178 psi standard, 128 psi minimum
Idle Speed: 850 ± 50 rpm
Fuel Pressure: 2.4-2.7 psi

CAUTION! Allow engine to cool before servicing. Disconnect battery when working on electrical components.

Transmission & Drivetrain

Transmission Type: 5-speed manual synchronized
Gear Ratios: 1st: 3.652, 2nd: 2.066, 3rd: 1.379, 4th: 1.000, 5th: 0.795, Reverse: 3.466
Transfer Case Ratios: High: 1.409, Low: 2.268
Front Differential: 3.73:1 ratio
Rear Differential: 3.73:1 ratio
Fluid Capacity: Transmission: 2.1 qt, Transfer Case: 1.6 qt
Fluid Type: API GL-4 75W-90 gear oil

Brake System

Front disc brakes, rear drum brakes with hydraulic system.

Front Brakes: Disc, 9.0 inch diameter
Rear Brakes: Drum, 7.9 inch diameter
Master Cylinder: Tandem type
Brake Fluid: DOT 3

Brake Pad Replacement: Minimum thickness 0.08 inch
Brake Drum: Maximum diameter 7.96 inch
Parking Brake: Adjust when lever travel exceeds 10-15 clicks

Electrical System

12-volt negative ground system with alternator and battery.

Battery: 12V 45Ah, negative ground
Alternator: 45 amp output
Starter: 0.8 kW
Fuse Box: Located under dashboard
Bulb Types: Headlight 60/55W, Brake 21W, Turn 21W, Parking 5W

Tip: Always disconnect battery negative terminal before electrical work.

Suspension & Steering

Rigid axle with leaf spring suspension and recirculating ball steering.

Front Suspension: Rigid axle with leaf springs, telescopic shock absorbers
Rear Suspension: Rigid axle with leaf springs, telescopic shock absorbers
Steering Type: Recirculating ball
Turning Radius: 15.7 feet
Wheel Alignment: Toe-in 0-0.24 inch, Camber 0°45'±45', Caster 3°±1°
Tire Size: P195/75R15 or 205/75R15
Tire Pressure: Front 22 psi, Rear 22 psi (normal load)

WARNING! Always check wheel lug nut torque (51-65 ft-lbs) after tire service.

Body & Interior

Removable soft top or optional hardtop configurations.

Troubleshooting Guide

Common issues and solutions for the 1987 Suzuki Samurai.

Symptom	Possible Cause	Corrective Action
Hard starting	Fuel filter, spark plugs	Replace fuel filter; check spark plugs and wires; verify fuel pressure.
4WD not engaging	Vacuum system, linkage	Check vacuum lines to front axle; inspect transfer case linkage.
Overheating	Coolant, thermostat	Check coolant level; replace thermostat; flush cooling system.
Brake pull	Calipers, alignment	Inspect brake calipers; check front end alignment; replace worn components.
Electrical issues	Ground connections, battery	Clean battery terminals; check ground connections; test alternator output.

Reset: Disconnect battery for 10 minutes to reset ECU if applicable.

Technical Data

Torque specifications and fluid capacities.

Component	Torque Specification
Spark Plugs	18-22 ft-lbs
Oil Drain Plug	22-29 ft-lbs
Wheel Lug Nuts	51-65 ft-lbs
Cylinder Head Bolts	56 ft-lbs (in sequence)
Drain Plugs (Differential)	22-29 ft-lbs

Wiring Diagrams

Complete electrical schematics for charging, starting, lighting, and accessory systems.

Color-coded wiring diagrams showing:
- Starting and charging circuits
- Ignition system wiring
- Lighting circuits (headlights, turn signals, brake lights)
- Instrument cluster connections
- 4WD engagement system

Note: Refer to original manual for full-size, detailed wiring diagrams.