I searched on here and did not find much info on which years are better, any common problems throughout the years, ect..
I am looking at buying one in the next few weeks and just looking for some info before I buy one.
I have an 87 model, and have owned it for about 4.5 years now. Most of the Suzuki Samurai's our there are 87 or 88 models. Sales rose very quickly as they became popular in the late 80's, but then Consumer Reports showed up to the party and fawked it all up. Everything you need to know is on Zuwharrie.com. If you have any specific questions, I'll try to answer.
One of the most common problems is the transfer case shifter bushing wears out and then the TC gets stuck in neutral or pops out of gear. The bushing is cheap and readily available off the net, so no big deal there. The transmisison shifter bushing and locater bolt also commonly wear out creating sloppy shifting. I replaced my shifter bolt last week and it is night and day improvement.
My personal opinion is that they are kind of underpowered in stock form. Popular motor swaps are the 1.6 8v and 1.6 16v motors from Suzuki Sidekicks or Geo Trackers.
The easiest way to put bigger tires on one is to do a spring over and then install some transfer case gears to correct the on road gearing as well as provide a nice low range for offroad.
All I can say about them is that they are extremely capable little 4WD's. My younger brother has an 88.5 with only a SPOA kit, 31's, a spooled rear, and a re-geared TC. It will do anything my TJ with 6" lift and 36's will do. (sometimes easier) I was highly impressed with what that little thing could do.
I just sold one.. I love them.. didn't have the budget for a 3rd 4x4.. The short time I had it, i was doing things with it that gave jeeps on 33's and 35's hell... It has a lot to do with the driver, but theres nothing like whiping around in these little steroid injected golf carts.. they are awesome and I will own one again...
The last spring over I did cost me about $15. I bought trailer spring perches from the local trailer supply place. The shock mounts are made into the spring plates so the shock mounts move with the spring over. The front shock mounts have to be removed and rewelded because of the way the flip works. Hard to explain but you'll understand when you look at it. Steering wasn't an issue.
I LOVE your description NCJeepin, not too far off.
T-Case gearing is a must. I had a bit of trouble in a "mud puddle" this past weekend; gotta love that trail rash. Locker up front will be next.
As for problems nothing between the years I know of. The flange on the drive shafts changed "around" year 88.5 from the small flange to large. I have small flanges on my 88.5. A lot of people say noting bigger than 33's on stock axles, but keep in mine 33s on a Zuk are relative to much bigger shoes on a jeep!
Great 4x4 to own. What else can you cut a 8" sewer pipe cap in half and have excellent diff armor
