RALLY TOPS INSTALLATION INSTRUCTIONS

Hardtop Type: 2-Piece Removable Hardtop
Truck Model: Suzuki Samurai (1986-1995)

General Safety Information:

Instructions – Safety

Your Rally Tops Hardtop will come with all the necessary parts to complete your installation. To safely lift and install this hardtop, you will need the assistance of at least one other person. The following instructions are examples of the installation. Please follow the instructions that are included with your Rally Top.

REMEMBER: It is the owner’s responsibility to insure proper installation and perform monthly maintenance checks of fasteners. Doing so will assure safe operation and long life of your upper hard doors.

Instructions – Warning

WARNING: The top on this vehicle is designed only for additional protection against the elements. Do not rely on the top to contain occupants within the vehicle or to protect against intrusion of foreign objects, nor injury during an accident. Make sure all brackets and screws are tight. Periodically check for tightness and retighten when necessary. Wear seat belts at all times.

Parts Provided:

  • 2 ea. Foam Stripes
  • 6 ea. 3/4″ Phillips Pan Head Screw
  • 2 ea. Self Locking nuts
  • 4 ea. Catches (closed)
  • 2 ea. Catches (notches)
  • 2 ea. M6 x 30 Socket Head Capscrew
  • 2 ea. Washers
  • 1 ea. Front Seal 46″ (Short)
  • 1 ea. Rear Seal 100″ (Long)
  • 1 ea. Tube Silicon

Instructions:

Follow the instructions and perform the steps in the sequence given. Shortcuts to the directions may result in an unsatisfactory installation.

1. Remove soft top. Remove bow screws and assembly.

2. Remove soft top retainer strips.

3. Install catch in factory holes in windshield frame.

4. Install notched catch (notch facing down) on the door jam rear factory hole

5. Mark the factory trim above the door jam on both sides and then remove the trim.

6. Cut the trim as marked and reinstall the two pieces that run vertically

7. It should look like this on both sides.

8. Starting at the cut end of the vertical trim, install the new short seal piece.

9. Continue installing the short seal and cut to fit at the other side.

10. Remove the screw holding the roll bar support and move it to the side about 3″.

11. Apply sealant under where the roll bar normally sits.

12. Reattach roll bar support.

13. Lay a bead of silicon across the bar and extent it about 2″ past the bar on both sides.

14. Totally seal this crack staring from the bottom of the flange all the way to the other end.

15. Seal in the valley, but don’t block the valley. This must allow the water to drain.

16. Seal all screw holes and any cracks along the sides and top.

17. Seal the corner so that water does not enter the cab, but flows down the channel.

18. Seal as shown. Take your time and get all the cracks and holes.

19. Seal in the front inside corners.

20. Remove roll bar padding.

21. Install foam tape to corners. Then cut 2″ of the channel, ofone end of the long seal. Leaving 2″ of bubble.

22. Start at one end & install the long seal. At the other end, cut the channel, leaving 2″ of bubble.

23. It should look like this. Now silicon over the foam tape.

24. Pull back the rear side panel, to allow for installation of clip.

25. Remove the second retainer clip from the panel.

26. Using a phillips screwdriver, punch a hole where the retainer was

27. Install the clip, using the nut and bolt. Snap the panel back in place.

28. Install the top.

29. Install the M6 Allen with washer. While pushing down on the top. Tighten Allen capscrew.

30. Adjust rear camlock to medium tension and lock.

31. Install front section and adjust all camlocks to medium tension and lock.

32. Don’t forget the keys! ENJOY!

Need more help?

Installing your Rally Top sport truck hardtop is a simple process, but we are always ready to lend expert advice.

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