5 Common Problems with the Suzuki Carry Truck (And How to Fix Them!)

The Suzuki Carry Truck has built a reputation worldwide for its compact size, versatility, and impressive reliability. Whether used for farming, construction, deliveries, or urban logistics, this mini truck often proves itself as a durable workhorse. However, like all vehicles, the Suzuki Carry isn't immune to mechanical issues, especially as it racks up mileage or is pushed to the limits in tough environments.

At Oiwa Garage Suzuki Carry, we’ve worked on hundreds of these dependable trucks and noticed recurring issues that owners often face. The good news? Most of these problems are easy to identify and fix — and in many cases, can even be prevented with proper maintenance.

In this guide, we’ll break down the five most common problems with the Suzuki Carry Truck and walk you through how to fix them.

1. Overheating Engine

The Problem:

One of the most frequent issues we encounter at Oiwa Garage Suzuki Carry is engine overheating, especially in older models or trucks driven in hot climates. Overheating can cause major engine damage if not addressed quickly.

Causes:

• Low coolant levels

• Radiator fan failure

• Thermostat malfunction

• Clogged radiator or cooling system

• Broken or slipping water pump belt

  
  

Symptoms:

• Temperature gauge rising into the red zone

• Steam coming from under the hood

• Loss of engine power

• Coolant boiling or leaking

  
  

How to Fix It:

Step 1: Check the coolant level in the reservoir and radiator (when the engine is cool). Top off with a 50/50 coolant-water mix if it's low.

Step 2: Inspect the radiator fan. If it's not spinning when the engine gets hot, test the fan motor and replace if necessary.

Step 3: Replace the thermostat if it's stuck closed. This part is inexpensive and easy to install with basic tools.

Step 4: Clean the radiator fins with compressed air or a hose to remove dirt and debris. In more severe cases, flush the radiator with a radiator flush solution.

Step 5: If the water pump isn’t circulating coolant properly, check the belt for wear or slippage. Replace the pump if needed.

Pro Tip:

Install a digital temperature gauge if your model only has a warning light — this helps you monitor the engine's behavior more accurately.

2. Transmission Issues

The Problem:

Suzuki Carry trucks, especially older ones with high mileage, can develop transmission issues — either with manual or automatic versions. Poor shifting or grinding gears can make the vehicle harder to drive and reduce fuel efficiency.

Causes:

• Worn clutch components

• Low or dirty transmission fluid

• Damaged synchros in manual transmissions

• Worn shifter bushings or linkage

• Faulty torque converter (in automatics)

  
  

Symptoms:

• Gear slipping or difficulty engaging

• Grinding or clunking sounds

• Hesitation during acceleration

• Transmission warning light (in newer models)

  
  

How to Fix It:

Manual Transmission:

• Clutch Replacement: If you feel slippage or if the clutch pedal feels soft, it may be time to replace the clutch disc, pressure plate, and throwout bearing.

  
  

• Fluid Change: Drain the old transmission fluid and refill with the recommended gear oil.

  
  

Automatic Transmission:

• Fluid Flush: Check the fluid color — if it’s brown or smells burnt, perform a full flush and replace with fresh ATF.

  
  

• Shift Solenoids: If the truck is stuck in a specific gear, test the solenoids for continuity and replace as needed.

  
  

Universal Fixes:

• Shifter Bushings: Replace any worn bushings to improve shifting precision.

  
  

• Linkage Adjustment: Sometimes, a simple adjustment to the shift linkage can solve engagement issues.

  
  

Pro Tip:

Always use OEM-grade fluids and components. Oiwa Garage Suzuki Carry stocks recommended lubricants that meet factory specifications.

3. Suspension Wear and Tear

The Problem:

The Suzuki Carry may be small, but it often hauls heavy loads. Over time, this leads to suspension problems, especially with worn-out bushings, shocks, and leaf springs.

Causes:

• Carrying loads beyond capacity

• Repeated driving on rough terrain

• Natural aging of rubber components

• Poor maintenance

  
  

Symptoms:

• Sagging rear end

• Bouncy or rough ride

• Uneven tire wear

• Clunking noises over bumps

  
  

How to Fix It:

Step 1: Inspect the leaf springs for cracks or sagging. Replace if they can’t maintain ride height.

Step 2: Test the shock absorbers by bouncing the truck’s corners. If it keeps bouncing, the shocks need replacing.

Step 3: Check all bushings and control arms for cracks or deterioration. Replace worn parts to restore handling.

Step 4: Make sure the wheel alignment is correct. Misalignment can cause uneven wear and stress the suspension.

Step 5: Consider upgrading to heavy-duty suspension parts if you often carry full loads. Oiwa Garage Suzuki Carry offers aftermarket options designed for durability.

Pro Tip:

Regularly inspect your suspension at every oil change to catch early signs of wear — especially if you drive off-road or on rural routes.

4. Electrical System Gremlins

The Problem:

Electrical issues can be frustrating and unpredictable. Older Suzuki Carry trucks are particularly prone to wiring problems, faulty switches, and dead batteries.

Causes:

• Corroded battery terminals

• Loose ground wires

• Faulty alternator or regulator

• Old or brittle wiring

• Defective switches or relays

  
  

Symptoms:

• Truck won’t start

• Dim or flickering lights

• Dashboard warning lights

• Battery not charging

• Intermittent issues with accessories

  
  

How to Fix It:

Step 1: Clean the battery terminals with a wire brush and tighten connections.

Step 2: Test the battery voltage — it should read 12.6V when off and over 13.5V when running. Replace the battery if it’s weak.

Step 3: Check the alternator output. If it's undercharging, replace the alternator or voltage regulator.

Step 4: Use a multimeter to test for bad grounds. Look for signs of corrosion or loose bolts at ground points.

Step 5: If accessories or lights aren’t working, test the relays and fuses. Swap them with known good ones to troubleshoot.

Step 6: Replace worn-out wiring harnesses or connectors that show signs of heat damage or wear.

Pro Tip:

At Oiwa Garage Suzuki Carry, we recommend installing an aftermarket fuse block for auxiliary accessories — it protects your original wiring from overloads and simplifies troubleshooting.

5. Rust and Body Corrosion

The Problem:

Rust is a serious issue, especially for older Suzuki Carry trucks imported from Japan or driven in coastal areas. These trucks often weren’t originally designed with heavy-duty anti-rust coatings for salty roads.

Causes:

• Exposure to salt (road or sea)

• Poor undercoating

• Scratches or chips in paint left untreated

• Condensation inside body panels

  
  

Symptoms:

• Flaky rust under the truck

• Bubbling paint near fenders or wheel wells

• Holes in floor panels

• Rusted brake or fuel lines

• Loose body panels or bumpers

  
  

How to Fix It:

Step 1: Inspect high-risk areas like the wheel arches, rocker panels, and undercarriage.

Step 2: Remove surface rust with a wire wheel or sandpaper and treat with rust converter.

Step 3: Use body filler for small holes, then sand and repaint with touch-up paint.

Step 4: For serious rust-through, weld in replacement panels or patch kits.

Step 5: Spray the undercarriage with a rubberized undercoating or rust inhibitor to prevent future damage.

Step 6: Rinse your truck with fresh water if you’ve been driving on salty roads.

Pro Tip:

At Oiwa Garage Suzuki Carry, we offer professional rust-proofing services tailored for Japanese imports. A little protection goes a long way.

Bonus: Preventative Maintenance Tips

While these are the most common Suzuki Carry problems, many of them can be avoided with regular upkeep. Here’s a quick maintenance checklist:

• Change oil every 3,000–5,000 miles

• Flush coolant every 2 years

• Inspect brakes and tires monthly

• Check suspension at every oil change

• Keep battery terminals clean

• Watch for fluid leaks regularly

• Use OEM or high-quality parts from trusted sources like Oiwa Garage Suzuki Carry

Final Thoughts

The Suzuki Carry Truck is one of the most reliable mini trucks on the market, and with proper care, it can run for decades. But like any machine, it's not without quirks. Fortunately, most problems are simple to fix — and many of them are preventable with a good maintenance routine.

At Oiwa Garage Suzuki Carry, we specialize in helping owners keep their trucks running strong. From affordable replacement parts to expert diagnostics and upgrades, we’ve got you covered. Whether you're hauling supplies or just commuting to work, a well-maintained Suzuki Carry will serve you faithfully for years to come.