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Old 04-03-2012, 01:23 PM  
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Default Just bought an SJ410... Need Help Please!

Hey guys,
I'm new to this, so forgive me if I am not entirely educated on Suzuki's yet, I just need some information!!!

Last week I bought myself a 1983 Suzuki Jimny SJ410 with a 1.3L engine (roughly 60,000kms on it) and a 4 speed manual transmission. Body is in overall decent condition, minus a few bumps, scraps, some rust and a beginner paint job, it looks pretty good. The engine runs great and the transmission shifts smooth. It has a front bush bumper, a 6000lb winch and 31" super swampers.

Okay so here's my issues:
The water pump rattles pretty badly, so I will definitely need to replace or rebuild it. And last night the transfer case got stuck in neutral, so idk if a bushing is wore out or off a spline or what's going on. And the tires rub when I cut the wheel hard (no biggie).

Now I am hoping to do the 1.6L turbo diesel conversion during the winter, but in the mean time I'd like to rig it to work for the summer.

I know that some Toyota, Suzuki, Chevy (Tracker) and Geo parts will fit into my Jimny... and that the parts for those are likely alot easier to find. So if anyone has ANY information on my options for an alternate water pump and transfer case that would be great.

Also I would like to rig up power steering, and I read that a Toyota steering box and pump will do the trick. Has anyone attempted this?
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Just bought an SJ410... Need Help Please!-img_20120402_190428.jpg   Just bought an SJ410... Need Help Please!-img_20120402_190323.jpg   Just bought an SJ410... Need Help Please!-img_20120402_190259.jpg  
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Old 04-03-2012, 05:44 PM  
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As far as I can tell your Zuke was equipped from the factory with a 1000 cc motor, Not the 1300.
Yours has the desirable shaft brake transfer case....I'd keep that....For sure. Rebuilds are a piece of cake...
You should have no problem ordering a water pump from your local auto supply.
Looks like a great little warior... Bet it's got some stories to tell.
I'd add an inch of offset to the wheels, that will eliminate the scrub.
I don't do the diesel thing so I'm the wrong guy to talk to about that.
Good luck...Boxcar...
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Old 04-03-2012, 06:47 PM  
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Thanks for the response!

Okay so I've got a 1.0L... good to know. As for the water pump, I tried to source one out but had little luck. I tried salvage yards and still... nothing. That's why I was hoping to find an alternative replacement. Oh well!

Do you have any information on the transfer case rebuild?
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Old 04-03-2012, 06:58 PM  
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You will probably have to special order the water pump. I had a SJ410 and had to special order the clutch through NAPA Auto Parts. I bought a 5 speed transmission from a 1.3 liter thinking the extra gear would help, but the tranny would not hook to the 1.0 Liter. I got 28 mpg out of mine. I liked it; it would run about 65 mph--pretty good for 1 liter 4X4.
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Old 04-03-2012, 07:15 PM  
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Overall I'm impressed with mine. If I can fix it up, I know it'll be a great 4x4. I have difficulty steering it, but I suppose I'll get used to it. Can't complain otherwise .

But thanks for the info, I'll check NAPA in the morning.
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Old 04-04-2012, 02:15 AM  
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I have a 1981 SJ410 with a 1000cc motor. Looks same as yours in the engine bay.
While you have the water pump off, do a flush of the radiator and engine block. Make sure you refill with a good anti-freeze/coolant suitable for alloy motors to stop corrosion. One thing we do in Australia is remove the heat box around the exhaust manifold along with the pipe that takes warmed air to the aircleaner. The reason being that the exhaust manifold overheats and cracks with the box in place. Possibly though you need the air heater in the Canadian winter.

The biggest tyres you can squeeze on the standard rims and still get clearance on full steering lock are 235 x 15 . I run mine at 12lbs pressure and can go anywhere off road. You can get bigger tyres on but they scrape on the body, make steering heavy, can damage the steering box and overload the front wheel bearings.

The other thing that is worth while is to put an extra in line fuel filter in the rubber fuel line just before the fuel pump. The Suzuki carburettor has fine jets that block up easily if you get any dirt in the fuel,

Last edited by johnfromperth; 04-04-2012 at 02:20 AM.
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Old 04-04-2012, 11:03 AM  
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Thanks for the info, I will definitely look into that. I'm assuming I could adapt the second fuel filter in relatively easy. I found a water pump at NAPA this morning, lucky me, so I'll be switching that out tonight.

Now I just have to rebuild the transfer case and I should be able to take it for a trail ride.
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Old 04-06-2012, 12:56 AM  
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Welcome to the addiction.
Be very careful installing that H2O pump that you do not let the timing belt go loose.
About your T/C if the problem is that it is locked in so called neutral :
Take the tower off the T/C from inside the rig. The rubber grommet comes off gently and push and twist the cap around the shift lever. Gently lift the lever out and shift the rods into phase(long screwdriver) and replace the shifter. You likely need a new 'shift sheet' (Suzuki talk for bushing) they are cheap and upgraded brass or poly ones can be had from after market places...mine came from Petroworks.)
This is not a big deal and you can drive a long time without one but be prepared to do the above to shift each time it happens before you fix it.
Even rebuilding a T/C is not all that hard if you know your way around inside
them. Think about adding lower gears if you do rebuild.
If you get jeep wheels with more offset than you have now, they will clear the body on a tight turn...some guys even turn the Suzuki wheels inside out but that makes airing down much more complicated...it will gain you a couple inches though.
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Old 04-06-2012, 11:08 AM  
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Re power steering:
If (big if) you can find a pulley for the front of your crank, to run the belt from, some use Tracker/Side kick power steering.
Before you hit the wreckers, though find that lump for the crank.
Mine works real good...easy on shoulders.
Will use some of the torque from the little l litre engine though.
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Old 04-06-2012, 01:21 PM  
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You'll need the hot air feed from the exhaust manifold or you'll get bad carb icing when it gets cold.
I still like the old SJ410s, on mine I had a 1 1/2" SU carb conversion and header and free flowing exhaust with an SJ413 distributor and coil. I also had LJ80 diffs to lower the gearing and a 5-speed gearbox from a later SJ410.
The 410 transmission and drive train is a lot weaker than the 413, I think that you make break it a lot with a TD engine.
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