Suzuki Samurai Choke Settings

The most common problem with Samurais is the choke setting.

Choke Operation

Perform the following adjustment with the air intake case removed from the engine, and the engine should be cold.

  1. Using your finger, check the choke valve for smooth movement.
  2. When the ambient temperature is below 77°F (25°C) and the engine is cold, ensure that the choke valve is almost completely closed.
  3. Ensure that the choke valve-to-carburetor bore clearance is within 0.01-0.023 in. (0.1-0.6mm) when the ambient air temperature is 77°F (25°C), and within 0.2-0.8 in. (1.3-2.8mm) when the air temperature is 8°F (40°C).
  4. If the choke valve-to-carburetor bore clearance is not within the specified ranges, inspect the choke spring, choke piston and each actuating link in the choke system for smooth operation. Lubricate the choke valve shaft and each actuating link with spray lubricant, if necessary.
  5. If the choke valve-to-carburetor bore clearance is still not within the specified ranges, remove the carburetor from the intake manifold, then remove the idle-up actuator from the carburetor.
  6. Turn the fast idle cam counterclockwise and insert a metal pin into the cam and bracket holes to secure it in place.
  7. Bend the choke lever up or down with a pair of pliers. Bending the lever up closes the choke valve, and bending the lever don opens the choke valve.
  8. Install the idle-up actuator, the carburetor and the air intake case.
  9. Start the engine and allow it to reach normal operating temperature.
  10. Stop the engine once it is warmed up, remove the air intake case, and ensure that the choke valve is fully open.
  11. If the choke valve does not open fully, the wax element or the link system is defective.