Looking for feedback as to a suitable setting.  Owners manual says 0 +/- 2mm which I assume is a total toe difference at the tire diameter.

I'm measuring 2mm difference front/back, toed-in, and am getting outer tire feathering at only 4000km and the sideways scrubbing pattern appears to indicate that the toe-in is insufficient. The vehicle is a nearly-new dealer demo and has not been offroad and still has the original factory alignment.

My experience (and the tire wear) says a bit more toe-in is reqd, perhaps 3mm.  The vehicle will not be towed.

Any experiences out there?

Welcome to Zukiworld.  Unfortunately I can't be of much help to you, my only experience is with my 02 Tracker which has 51,000 miles, the original factory alignment and the (crappy) original factory tires.  Oh and it has been off-road and I haven't had any problems with the alignment or tire wear.

Good luck, hopefully someone else around here will have more helpfull input.

Thanks for the welcome!  After a bit more web research it looks like the tire wear pattern I have is actually indicative of *excessive* toe-in rather than insufficient toe-in.  That's a great relief as I would hate to think that the stock specs were not somehow applicable to my vehicle.

I have some homemade tools and a technique which I developed when I had a Nissan Xterra.  It gives very repeatable and hopefully very accurate toe-in measurements.  That vehicle was happy at +4mm, but the measurement of course is static and so is only relative to what actually happens when the truck is in motion.

Since I'm at the most toed-in end of the specification range on the Suz (+2), at least I know which way to go now.  I'll probably try +1.0 mm first.

My sister has '95 Vitara (Escudo) and that thing eats front tires for breakfast!

EDIT: well, I think I'm pretty close at about +0.7mm.  It's a very sensitive adjustment - the entire 4mm range is covered in only 1/8 turn of the tie rods!

EDIT AGAIN:  A few weeks later, tire wear is minimal and handling is as good as it is going to get, so I'm going to leave it at the 0.7 to 0.8 mm.