RALLY TOPS INSTALLATION INSTRUCTIONS

Hardtop Type: 2-Piece Removable Sport Hardtop
Truck Model: Suzuki Samurai (1986-1995) | Suzuki Samurai LWB (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 Angle Clips
  • 2. Flat Clips
  • 4. M6 x 20 Phillips Pan Heads
  • 2. M6 x 30 Button Head Socket Cap Screws
  • 2. 1.25” Cut Washer
  • 2. 5/16”-18 x 1” Button Head Cap Screws
  • 2. 3/8” Silver Washers
  • 1. 46” Front Body Seal
  • 1. 8 Pieces weather stripping
  • 1. Tube Silicone
  • 1. M4 Metric Key
  • 1. 3/16 Allen Key
  • 2. Adapters
  • 1. 96” Rear Seal

Tools/Materials Required:

  • 1. Tube Dispenser
  • 1. Phillips screwdriver
  • 1. Scissors

Instructions:

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

1. Remove canvas soft top.

2. Remove rear bow screws & remove bow assembly.

3. Remove soft top retainer strips.

4. Install angled latch hooks in factory holes in the windshield frame using M6 x 20 screws.

5. Install flat latch hook (notch facing down) on door jam rear factory hole, using M6 x 20 screws.

6. Mark the factory trim above the door jams on both sides and remove trim.

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

8. It Should look like this on both sides.

9. Starting at the cut end of the vertical trim. Install the new 46” front body trim piece, all the way to the other side. Cut at the other end so that it meets up with the other vertical end.

10. Remove the rear screws holding the roll bar supports and move the roll bar to the side about 3 inches.

11. Using the supplied sealant, apply sealant under where the roll bar sits when it is screwed in.

12. Reattach the roll bar support. It should look like this when done.

13. Seal all the holes in the front flange valley, so that any trapped water will exit outside of the cab area.

13a. Totally seal this crack starting from the bottom of the flange all the to other end.

13b. Lay a bead of silicon across the bar and extend it about 2” past the bar on both sides.

13c. Seal in the front inside corners.

13d. Seal all screw holes and any other cracks along the sides and top. Take your time and do a good job.

13e. Seal all the holes in the front flange valley, so that any trapped water will exit outside of the cab area.

14. Attach a piece of foam to the corners as shown.

15. Using a combination of sealant and the supplied foam, seal the front corners of the windshield.

16. Remove the rear roll bar padding.

17. Remove the roll bar side support bolts then remove the padding and reinstall the bolts.

18. Cut the u shaped channel off the end of the seal about 1.5” from the end.

19. Start the rear seal on the flange so the bubble extends horizontal about 1.5”. Then continue installing the seal on the flange. At the other, cut the seal 1.5” past the end. Then cut 1.5” off the u shape and lay the bubble flat so it looks like the other side.

20. Now put a piece of foam in the corner and silicone the corner as shown.

21. Install the bracket in the rear mounting hole. Then secure using the 2 supplied screws.

22. Using two people, place the rear section on the Samurai. It must be in the position shown and then lowered into place. Reverse the procedure to remove the top.

23. Install the forward M6 x 30 button head cap screw and 1.25” cut washer. Do not tighten all the way down.

24. Install the 5/16” button head bolt and 3/8” silver washers in rear hole. Do not tighten the bolt all the way down.

25. Adjust the front and rear so it’s flush with the body line of the Samurai and tighten the bolts.

26. Install the front section and secure the cam-locks. Latch the side cam-locks first and then the front ones. Cam-locks should be adjusted for medium tension.

27. Your Done. 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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