Hello all! I am a new member and the proud new owner of a 1984 SJ410. The only two things I'd like to do something about are fixing the carburetor and seeing if it's possible to add a 5th gear.

First the carb.... the only problem I see with it is that when (and if) it idles, it is really rough. The guy I bought it from hadn't driven it in two years. It didn't pass emissions, so he just let it sit. When I went to pick it up he had to give it a shot of ether and it started right up. There isn't any hesitation when I'm accelerating. I live in an area where I don't have to pass emissions, but it would be nice to not have to keep the engine revving while slowing down or at a stop. Should a carb kit solve the problem? CarQuest told me it was $40 for one.

Now for a stretch.... I read on a post by someone in Puerto Rico http://www.carsurvey.org/review_90200.html that you could take a 4-speed SJ410 and a 5-speed from a Samurai and make something that would give the SJ410 a 5th gear. I know the 5-speed from a Samurai won't match up with the 1.0 L, but does what this guy says make any sense? Has anyone heard about such a modification?

In case you didn't want to click on the link, here's what he says:

First, you need a Samurai transmission (5-speed and a reverse), get the factory manual, and a copy of the parts catalog of both, the Samurai and the SJ 410 just for reference. You can get those in the auto parts near you. Well, the thing is, you will make one transmission out of two. This is how you will do it! Take the case assembly, the upper and the lower, the input shaft(nt:23)and the input shaft bearing retainer of the SJ 410 and install in those parts the case extension, the forks and the rest of the gears of the Samurai transmission, follow the steps in the Factory Service Manual, and you will have a 5 speed SJ 410. Have in mind, that you'll have to cut about one inch in the hole at the floor, were the shifting lever case goes, between those bolts next to you. That's because, the "Sammy" trans, is one inch longer than the SJ 410 Due to the Gear Shifting forks assembly.

It may be the idle jet is plugged up and needs to be cleaned. I would rebuild the carb if it has been sitting more than six months. the old fuel drys up and can come loose and plug the carb jets.

If you are in the US, order your parts from Hawk Suzuki instead of Car Quest.  For some reason the Car Quest books show the SJ-410, but all the parts are for the SJ-413 aka Samurai.

As for the 5 speed, your basically taking a bunch of guts out of the Samurai transmission and putting them on the back half of the SJ-410 transmission.  It will probably work, but I wouldn't bother.  If you want to be able to cruise at 60-70 down the road, just swap in a 1.6L or an engine from something else.  The 970cc that your vehicle is blessed with is one hell of a work horse, but power house it is not.  I run a 6.5:1 transfer case and 5.12 gears and still run out of power running up hills in 3rd gear and low range if I can't keep the RPM's above 3K.  In high range I don't have enough power in 4th gear to run up hills, 5th gear would be useless.  Then again, a 5th gear would be nice in low range...

Thank you Drone637 and Ogarac. I'll give Hawk a call because I didn't see a carb kit on the website. I am a little suspicious about CarQuest not understanding the brilliance of my 410 

As for the tranny...I think I'm interested to see if I can add the 5th gear. This is my commuter to work which consists of 4 miles at about 45mph. It would just be nice to be cruising at 2200 rpm rather than 3200. I have 2 extra 410 transmissions that came with the vehicle so I wouldn't mind donating one to the cause. I would just have to locate a 5-speed from a Samurai, but my question remains...is it really possible?

I've never really done anything with transmissions other than replace one in a minivan. Where can I go to learn more about doing something like this? (PS, I really like pictures).

Off the subject Drone637, I checked out your off road club site and just wanted to say more power to you guys up there in the northwest. I was born and raised in Edmonds and wish I was closer. It rained here in Arizona today and it made me homesick. Thanks for your feedback.

I've never heard about that modification but UK 410s had a 5 speed gearbox after 1985 or thereabouts.

Thank you Drone637 and Ogarac. I'll give Hawk a call because I didn't see a carb kit on the website. I am a little suspicious about CarQuest not understanding the brilliance of my 410 

At my local Car Quest they where able to find part numbers through the Canadian branch, but whenever they ordered anything it never fit. 

As for the tranny...I think I'm interested to see if I can add the 5th gear. This is my commuter to work which consists of 4 miles at about 45mph. It would just be nice to be cruising at 2200 rpm rather than 3200. I have 2 extra 410 transmissions that came with the vehicle so I wouldn't mind donating one to the cause. I would just have to locate a 5-speed from a Samurai, but my question remains...is it really possible?

I think it is.  Having torn apart the 5 speed it looks just like the 4, only with some extra parts slapped on the back.  Since red line on the engine is around 5800 or so, I wouldn't worry about the extra revs.  But hey, it might be a fun experiment. 

I've never really done anything with transmissions other than replace one in a minivan. Where can I go to learn more about doing something like this? (PS, I really like pictures).

A service repair manual would probably do it.  Suzukiinfo.com and Acks Faq both have manuals available for the Samurai transmission, but I haven't found one for the SJ-410.   I picked one up from Hawk Suzuki a few years ago, but you do pay a bit for them.

Off the subject Drone637, I checked out your off road club site and just wanted to say more power to you guys up there in the northwest. I was born and raised in Edmonds and wish I was closer. It rained here in Arizona today and it made me homesick. Thanks for your feedback.

Thanks.    We have some video online as well as a picture gallery.  The closest I've come to wheeling in Arizona has been one trip to Johnson Valley.  If I lived in your area I would probably be building a pre-runner.