To See Or Not To See
Weak link: Visibility on the trail.
Models affected: All.
What happens: While SJ410 Suzukis featured fold-down windshields, the more common Samurai were not equipped with this feature. This denies Samurai owners of better visibility on the trail, as well as the ability to move the windshield frame and glass out of harm's way on the really tough stuff.
Strong fix: Rather than envy their Jeeper friends, Samurai owners can retrofit their rig with OEM fold-down hardware from Rocky Road Outfitters.
Contact: Rocky Road Outfitters.
Brain Transplant
Weak link: Electronic Control Module
Models affected: '91-'95 EFI models.
What happens: The electrolytic capacitors in the ECM discharge a corrosive fluid that can eventually damage the circuit board if left unchecked. This leaves you with a motor that will not function.
Strong fix: Petroworks can repair your fried ECM for a fraction of the price that the dealer demands.
Contact: Petroworks.
Lack of Power
Weak link: Underpowered 1.3L motor.
Models affected: All.
What happens: Samurais have never been known as powerhouses, relying more on their size, weight, and gearing to supply forward motion. Sometimes, though, there is a muddy hill or sand dune in your path and the only way to conquer it is with horsepower. Fortunately, there are several options to supply your Suzuki with more power than the stock 1.3L.
Strong fix 1: Calmini offers conversion kits to utilize a 1.6L motor from a Sidekick or Geo Tracker (don't laugh-Mike Shaffer won the RCAA championship with one of these mills in 2002). The kit includes an adapter plate to your stock transmission, a new motor mount and spacer, all hardware, and an optional fuel pump
Strong fix 2: Acme Adapters offers everything you need to swap a 1.5L, 1.6L, or 1.9L naturally aspirated or turbocharged Volkswagen diesel motor under the hood of your Samurai. The kits come complete with all of the hard-to-find parts and adapters to make this swap possible. The kit also includes a detailed installation manual with color photos to help you through the process and assist you in locating the common parts needed for the swap, saving the customer money in the process.
Strong fix 3: For those of you with rampant power addictions, Lightning Conversions offers kits to swap a 4.3L Chevy Vortec motor in your Suzuki. Basic kits include driveshafts, motor mounts, a tranny mount, and a throttle cable, while more complete kits are available with everything from exhaust manifolds to oil pans to full-tilt turnkey motors.
Contact: Acme Adapters, Calmini, Lightning Conversions.
Spring-over Symptoms
Weak link: Driveshaft length.
Models affected: All.
What happens: Unlike Dana axles, Suzukis use a pinion flange instead of a traditional yoke to connect the driveshafts to the axles. Once a lift kit is installed, the driveshafts are often too short and can come apart under extreme articulation.
Strong fix: To save the expense of new driveshafts, Petroworks offers billet-aluminum extensions that install between the driveshaft and the pinion flange. The driveshaft extensions are made of anodized aluminum and come with all necessary mounting hardware.
Contact: Calmini, 800/345-3305, www.calmini.com.
Full of Fuel
Weak link: Range of travel in the backcountry.
Models affected: All.
What happens: While Samurai motors use fuel sparingly, extra capacity is still appreciated on extended trips. As owners know, these small rigs do not have a surplus of space to mount heavy jerricans.
Strong fix: Petroworks offers a DOT-approved 15-gallon polyethylene gas tank with five gallons more capacity than stock. A 3/16-inch-thick, zinc-plated steel skidplate is included and there is no loss of ground clearance relative to the stock tank.
Contact: Petroworks.
Bad Brakes
Weak link: Leaking master cylinder.
Models affected: All.
What happens: Over time, the Samurai master cylinder will start to leak brake fluid. Not only is low brake fluid a danger on the road, but the fluid is extremely caustic and will eat through any paint it encounters.
Strong fix: Petroworks can provide you with new grommets for your master cylinder that will prevent leakage. The grommets are inexpensive and easy to install, remedying a potentially dangerous situation.
Contact: Petroworks.
In The Clutch
Weak link: Stock clutch.
Models affected: All.
What happens: Once you add those bigger tires and a high(er)-horsepower motor, the stock clutch is subjected to loads it was never intended for. The problem is made worse when the vehicle does not have the proper gearing and the clutch needs to be slipped when four-wheeling.
Strong fix: Most high-performance clutches are designed for racing and increase clamping force at high rpm. This is not of much use for the four-wheeler, as we need to be able slip the clutch at low rpm and not have it fail. Petroworks offers a clutch designed specifically for 'wheeling that has a twin-friction organic/ceramic disc that engages positively but does not grab.
Contact: Petroworks.
Steer You Straight
Weak link: Manual steering.
Models affected: All.
What happens: Samurais don't come with a lot of frills from the factory. This is a breath of fresh air with the current manufacturer trend towards active suspensions and traction control. While the simplicity keeps the Samurai inexpensive and reliable, creature comforts such as power steering make turning big tires much more enjoyable.
Sturdy fix: Calmini offers a kit to retrofit the power steering from a Sidekick onto your Samurai. The kit comes complete with all laser-crafted brackets, heavy-duty U-joint, and specialty hardware and spacers. The box, pump, and reservoir can be sourced locally. With easier steering and the use of Suzuki parts, this upgrade is an easy decision to make.
Contact: Calmini.