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Old 04-19-2015, 09:41 AM   #1 (permalink)
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Default 1986 Suzuki Samurai Build Updated

Hello. My first thread wasn't the best so I'm starting over. Ill start off with a little about me. I am a 18 year old kid about to graduate and I purchased my first samurai about 3 months ago. I was looking to buy a four wheeler when I heard about the samurais and how versatile they are. After searching for a couple of days I found a decent one not to far from where I lived. I had no clue what I was doing or what I was getting myself into. Anyways I picked it up for around $2400, not sure if it was a good deal but it doesn't really matter to me, first time rookie mistake if I paid to much. My only worry after I bought it was the previous owner ground down the front hubs to be able to fit big wheels and lower it. Because he ground down the hubs there were no lockers to test out the 4x4, talk about sketchy. Brought it home on a late saturday night and couldn't wait to drive it around the next day.
On the trailer bringing her home.
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First things were to add a couple accessories.
Inclinometer for those oh sh*t moments
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The headlights were terrible! You couldn't see nothin in at night so some $30 led pods from amazon were a must.
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A jeep came into where I work a few weeks before and it had a set of pods set up just like this and I thought it looked cool so thats where they went.
As a 18 year old kid I have a wild imagination, always thinking of things I could do to my new toy. I knew I wanted to lift it and put some new shoes underneath it, but where do I start. After searching for a while, I found two lifts that stuck out to me. SPOA and a coil system or whatever its called. Sorry I still have a lot to learn. Also as a young teen I tend to spend my money as fast as I get it it seems so I knew from the start of this I would have to budget this project, and we all know how that goes. So SPOA it was! Me and a friend spent one saturday installing the low range SPOA kit, and I have to say it took a while, but to my surprise was pretty easy.
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Thats me under it tightening up the drive shaft bolts after putting in the spacers. While looking for lift kits i found out about the steering issues that come when you lift the samurais. I will be fixing it but for now it works. Also the stock shocks were left on the car as well. Once again I will be addressing that but for now it will work.

Last edited by Brodyb; 04-19-2015 at 09:45 AM.
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Old 04-19-2015, 10:33 AM   #2 (permalink)
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First off $2400 for a running Samurai that is not a rust bucket is a pretty fair deal, if not downright great. SPOA is nice but a coil spring setup can get very spendy and probably not necessary unless you plan to do some insane rock crawling. Mine has leafs and I'm shocked by its capability each time I go out and I do quite a bit more than fire trails. What you have there IMHO is already pretty decent, much more and you probably hit the point if diminishing returns unless you have a large budget.

Take it out and make friends with it, you will be surprised by what it can do. Anymore lifting or bigger tires might be a bragging right that lightens your wallet but if you really need more off road performance than what you have in the pics I believe lockers are a fantastic thing.

Regarding lighting, I tried to get by with as few lights as possible, the OEM headlights are shyt to be sure. I ordered some of the cheap Hella knock-offs for $20 each from Summet and put in some Osram Nightbreakers and they really light up the world and are DOT legal. Please do not but HIDs in them, its a dick move, trust me! I use the 6" offroad lights on my bumper and if the HL are not enough in the dark mid-nowhere these will light it all up. I DID use HID conversion kits in the aux lights. these two lighting systems have negated the need for pods and a bunch of stuff all over the body, I wanted to avoid the all expense paid trip to JC Whitney look with crap screwed on everywhere. Definately look for the headlight relay mod and do that along with upgraded headlights and you will be surprised how nice it is. Besides the more lights you use the more lights that can be bitten off by trees, I even pull my wiper blades before going wheeling but I live in the sticks here, lots of very angry trees. Oh yea, I do have a copy of the schematic for the headlight relay mod if you need it, PM me and I'll send it along.

Do remember that whatever money you put into this vehicle, you are highly unlikely to get it back when you sell. It seems to be the nature of offroad vehicles. Enjoy the ride, its pretty sweet.
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1986 Suzuki Samurai Build Updated-dsc02066.jpg  
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Old 04-19-2015, 08:24 PM   #3 (permalink)
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Quote:
Originally Posted by caseyjones955 View Post
First off $2400 for a running Samurai that is not a rust bucket is a pretty fair deal, if not downright great. SPOA is nice but a coil spring setup can get very spendy and probably not necessary unless you plan to do some insane rock crawling. Mine has leafs and I'm shocked by its capability each time I go out and I do quite a bit more than fire trails. What you have there IMHO is already pretty decent, much more and you probably hit the point if diminishing returns unless you have a large budget.

Take it out and make friends with it, you will be surprised by what it can do. Anymore lifting or bigger tires might be a bragging right that lightens your wallet but if you really need more off road performance than what you have in the pics I believe lockers are a fantastic thing.

Regarding lighting, I tried to get by with as few lights as possible, the OEM headlights are shyt to be sure. I ordered some of the cheap Hella knock-offs for $20 each from Summet and put in some Osram Nightbreakers and they really light up the world and are DOT legal. Please do not but HIDs in them, its a dick move, trust me! I use the 6" offroad lights on my bumper and if the HL are not enough in the dark mid-nowhere these will light it all up. I DID use HID conversion kits in the aux lights. these two lighting systems have negated the need for pods and a bunch of stuff all over the body, I wanted to avoid the all expense paid trip to JC Whitney look with crap screwed on everywhere. Definately look for the headlight relay mod and do that along with upgraded headlights and you will be surprised how nice it is. Besides the more lights you use the more lights that can be bitten off by trees, I even pull my wiper blades before going wheeling but I live in the sticks here, lots of very angry trees. Oh yea, I do have a copy of the schematic for the headlight relay mod if you need it, PM me and I'll send it along.

Do remember that whatever money you put into this vehicle, you are highly unlikely to get it back when you sell. It seems to be the nature of offroad vehicles. Enjoy the ride, its pretty sweet.
Thanks for the advice! I think ill take you up on that relay mod for sure. How do you like your bumper? I was looking at getting the same one, winch and everything. I emailed zukoffroad where I found the bumper and asked if they could send me one with no cut outs for the lights so I could cut my own for different lights and LED flush mounts. I know more pods put they're just so addicting
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Old 04-19-2015, 09:26 PM   #4 (permalink)
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I hear ya on the pod thing. I love the bumper. You can get them cut for the common LED light fixture, its cheap and easy, I have LED lights/blinkers on all corners, you will need to replace the flasher with IIRC an EP34. There really isnt much room behind the bumper. If you have access to a plasma cutter or something it should be to bad.

I really like the bumper and the winch. The customer service I got while buying the bumper was well above and beyond. You wont go wrong with this setup.
I'll PM my email so you can get the schematic.

Tony
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Old 04-20-2015, 07:17 PM   #5 (permalink)
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So I took the Sami out for a little fun at a friends house and let's just say it didn't end well.
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Something in the carb or throttle cables kept getting stuck and caused it to rev out without stopping until you turned it off. You turn it on, it would idle for a few seconds then rev out again. We finally figured out how to limp it back, if you threw it in gear in the few seconds it idled normally and took off it would idle fine and you could drive but as soon as you touched the gas it would rev out and you would have to start over again. It sat at my work for a couple of weeks because I got busy and the starter went out, or so I thought. Winched it on a trailer and brought it home. After messing with it for a while I had some help from my dad by skipping the starter cylinoid using a metal chizzle and it kicked right off. So then I came to the conclusion that the cylinoid was bad, but just for fun I tried starting it with the key and it fired off right away like nothing had happened, and no revving either! Beats me what was wrong but I have a new weber carb sitting in the garage waiting to be put in cause the old one(original) is just warn out. I also got my homemade door panels on. Just a piece of wood paneling and some Bedliner, I think they turned out alright.
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Old 04-21-2015, 10:27 AM   #6 (permalink)
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Do a search for "clicky starter fix", its a common ailment with an easy fix.

The revving thing I'm not sure without putting my hands on it but it sure sounds like fuel management issues. I have never played with a Sami carb before but I hear they can be finicky. Does the throttle cable operate the linkage properly, does it snap back without sticking or binding when you let it go? Give it a once over for vacuum leaks, the hoses are nearing their 30th birthday.

Luckily it's all a pretty basic and solid vehicle and the common issues are very well covered here, also there are many here that have vast knowledge.

Is this going to be your first project vehicle?

Tony
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Old 04-21-2015, 11:40 AM   #7 (permalink)
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Default Same Carb problem

Brodyb,
I am having a similar problem with my carb. When I took it on a drive the last three times the carb throttle seems to hang open when you are going through the gears. When I accelerate, as I am shifting, the engine RPM continues to redline. This seems to happen only when I am being aggressive on the throttle. It's scary when the motor is going to WOT and you don't even have your foot on the gas!! I have checked the linkage and the throttle cable and can find nothing wrong. No stiff spots, no hang ups. When I'm at my shop I have run the engine and can not duplicate the problem. It only seems to do it when I have it on the road.
So, if you find out what the problem is, let me know. If I can find out what is causing my problem, I will let you know. Good luck with your build.
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Old 04-21-2015, 02:51 PM   #8 (permalink)
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Default Carb sticking

I had an issue with a Weber 32/36 carb I put on a Gen I Montero I used to have, and had the same issue with the Weber that's on my Sammy, in that the throttle wouldn't "snap" back. My solution to both Weber applications was to install a return spring that would help the linkage snap back like it's supposed to. I'll take a pic of the spring that I put on the Weber on the Sammy and post it later.

If it dies, that could be a fuel issue. But if it keeps running or even revs higher, that could be solved with an external return spring. It's a cheap and easy fix, certainly can't hurt...
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Old 04-21-2015, 05:49 PM   #9 (permalink)
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Thanks for all the help guys! As for the starter ill check into that clicky starter fix sense that sounds like the problem. Everything with the starter and carb are working fine now. No problem really starting it except for once or twice it will just click but then I try again and it kicks right over, and the carb or throttle or whatever was making it rev must have fixed itself because I have not had it happen once sense I got it running again. Like I said I have a new weber carb just like social said that should be installed soon. Ive been so busy getting ready for college that Im trying to balance it with the time I put into the sami, and trying to stay out of trouble with the parents if I spend TOO much time on the sami and not enough on school.
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Old 04-21-2015, 05:52 PM   #10 (permalink)
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Default Carb springs

Two pics of the spring I put on the Sammy's Weber carb. The throttle closes down like it's supposed to now.
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