4x4 Mag - Feature Article - Suzuki SJ Offroad Modifications

Feature Article

Suzuki SJ Modifications for Off-Road Use

One of the great things about off-roading is the way that you can purchase a standard road going 4x4 which can do a number of on-road chores yet still be enjoyable to drive off road without any need for modification. However, as those who have been bitten by the bug know, once your off-road enthusiasm is kindled your chosen 4x4 invariably becomes modified, some more seriously than others and often dictated by the wallet !

This month we're featuring two Suzuki SJ410 Jeeps. The owners of each had a different schedule and set of aims which dictated the modification they chose, with the common desire to create a Suzuki that was more capable than the standard version.

Both are the SJ410 models, with only 1,000cc and a four speed gearbox, but a short wheelbase coupled with a light weight make an agile vehicle and these engines are really willing. We'll look first at the SJ which was to be modified for predominately off-road use, but had to be driven on the road to and from events and green-lane outings. With this is mind the vehicle had to remain "respectable" looking and road tractable and so only subtle modification were chosen mainly confined to the drive train.

Since tyres are the first point of contact with the ground these were the first modification. A larger set of wheels and tyres were fitted, 215-15 Tracker Mud Terrain Pattern tyres were ideally suitable, with the radial pattern for road adhesion yet a good clean tread for mud and difficult surfaces. This modification resulted in approximately 2 inches more under axle ground clearance. This was coupled with a Rancho 2.5" suspension lift kit which gave greater underbody ground clearance and Explorer Pro-Comp shock absorbers and steering shock absorber looked after the extra axle articulation and handled the jolts more easily than the standard system. The suspension lift in effect protected the underneath of the vehicle. So, the jeep has more ground clearance and better tyres basic modification to assist its off road progress.

In the photograph you can see the additional ground clearance when compared with the green Suzuki which is also fitted with 215-15 tyres, but doesn't have the suspension lift.

Finishing off the vehicle the front bumper was removed to increase the entry angle and a custom bull bar with towing point was added. At the rear a tow bar with towing jaw gave essential safe couplings for ropes and shackles. The rear towing bar was designed to help protect the fuel tank from damage.

The downside of the suspension modifications was a more pronounced tendency to wander and "tramline", especially on motorways and dual carriageways and a vagueness to the steering on wet road surfaces. Whilst cornering you had to take into account the increased height of the vehicle, and of course, those tyres generated extra road noise, but remember the standard SJ isn't the most comfortable vehicle on the road.

We look now to the other end of the spectrum. An SJ travelling everywhere on a trailer, with no on road requirement and therefore designed purely for off-roading with external modifications to suit the increased demands of the driver. We thank Peter Shepherd for this "first hand" account of his SJ...

"Where do you begin when you are describing an amazing little car like the Suzuki SJ410..."

To answer that question, I suppose that I had better start back in May or June of last year, when the 4x4 bug bit me and I decided that it was time I bought myself a car just for off road use, instead of using my trusty Isuzu Trooper all of the time. And so after cruising the pages of Autotrader for a few weeks I finally came across the SJ you see above in the For Sale section of the "4x4 Funday Ltd" handout. One telephone call later and I was on my way to Castleford to view the "well used off roader".

It had obviously seen a "bit of action" somewhere along the way, but it still had 10 Months MOT, and had some modifications to suit off road use already done, fuel tank moved up into the back, carpets removed, better seats etc. So the cash changed hands and I dragged it back to base with the trusty Trooper.

Closer examination revealed that the first problem was that the previous owner had used the car without any air filter at all, not even an empty housing, which obviously wouldn’t do for my intended use. So it was decided to go the ‘whole hog’ and fit a raised air intake, which thanks to the local DIY Store and a very large hole cutter, proved to be quite a succesfull job, a few plastic elbows, a bit of silicone and a trip to the local scrapyard for a length of flexible hose and the job was done, all topped off with a nice plastic soap dish turned upside down and painted to match!

And so the first outing with the yellow peril arrived, and although she performed well, the tyres (Tracker All Terrains) proved to have very little grip, and the missing dirt plate on the Gearbox bell housing allowed the clutch to fill up with mud and become impossible to disengage! Not to worry, back to base behind the Trooper again, and a call to the local Suzuki Jeep dealer (I.G.W Bolton) and the missing dirt plate was delivered next day. With the gearbox out the clutch was ‘de-gunged’ (amazing how much you can get in a Suzuki bell housing!!) and all assembled again just in time for the arrival of the new tyres.

A call to John Craddock (Off Road Vehicle Parts Supplier) had arranged for a set of what he called a "really good mud tyre" to be delivered, and when I saw the 215 x 15 Super Mud Pluggers they had sent, I knew exactly what they meant by good mud tyres. Two hours later the Suzuki sat 2 inches higher and looked pretty mean, I expected to have slight clearence problems on the front, but that was acceptable considering the extra grip I expected to get.

The next outing in the mud was to Briercliffe, nr Burnley, Lancs., with the "4x4 Funday boys", and the little Suzuki proved that even though she only had that little 1000cc engine, nothing could stop her, and many a Landrover was put to shame that day.

After Briercliffe, I realised that with all that grip and go anywhere ability, the Suzuki should really have a roll-cage for that ‘just in case’ situation, after all, the Suzuki isn’t the most stable 4x4 available.

Luckily for me, we had a machine for bending box section where I work, and so a few prototypes, lots of grinding, and plenty of welding later, the Suzuki had an internal rear roll cage welded securely to the chassis at four points, and probably stronger than necessary. This roll cage has since been joined by a full front cage, again welded to the chassis through holes in the floor, and also to the bodywork where necessary.

A new front grill was fitted, which was again made utilising machinery in the factory where I work, and although you can’t see it in the pictures, believe me it looks great and attracts a lot of attention.

As you can see, the SJ certainly looks the part, and now she really puts some expensive machinery to shame, with amazing grip, a light weight and such a willing little engine, she’s a go anywhere 4x4!

Plans for the future include a winch mounted behind the front seats and feeding out through the welded up half rear door, raised suspension and moving the radiator to the rear out of harms way.

I don’t think I will really ever stop modifying the SJ, a bit here and a bit there, and who knows, one day it might grow up into a Range Rover Bob tail!!