Maximum weight on Jimny's roof and rails

I agree, I think that the weight limit has nothing to do with how much weight the bars can physically support. It's how much Suzuki thinks you can safely carry while staying in control of the vehicle. A lot in the manual makes me think they were very paranoid the thing would role over. I'm pretty sure it says something to the effect of: "avoid tight bends whenever possible".

I have a roof rack on at the moment and this got me worrying about how much weight the plastic bars could take... Turns out if I hold onto one of the bars in the middle (where I expect it's weakest) it can take my entire body weight (nearly 90kg on the one bar)

So even though they are plastic, they're actually very strong. I agree with you; I think the issue is that the Jimny has a high centre of gravity and rather poor handling at speed anyway, so they don't think it would be safe to carry more than 30kg in such a elevated position. No doubt they're correct.

I contacted Suzuki directly and they confirmed that 30kg is the maximum load for the roof regardless of whether you are using the original plastic bars or not. The same limit applies to the Gen4 which doesn't come with roof bars.

Suzuki's apparent paranoia can be explained by the bad press they received over the elk test where swerve tests seem to indicate that the Gen.2 had a tendency to either lift inside wheels or even roll over. Properly driven tests vindicated Suzuki but mud sticks.

The roof loading specified by Suzuki will be based on tests and although it may appear to be low it must take into account evasive manoeuvres that suddenly present themselves. Bosoneks comment gives an accurate account of just what happens when you exceed the stated limit and all hail to him for telling us the story.

I have seen two motors roll over on RTV trials, one a Defender and two, my own Gen.2. Once it started, there was no way to stop it, so be warned.

Roger