Instructions Created by an: Suzuki Samurai Roof Rack Kit for Hard Top, Tin Top by Low Range Off Road (SKU# SEB-RRTT) Installation Instructions CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. Suggested Tools: For additional copies of these and other instructions go to: www.lowrangeoffroad and click on the Instructions tab. Allen Wrench: 5/32 (Supplied) Ratcheting Combination Wrench: 1/2, 9/16, & 12mm, Sockets: 1/2, 9/16 & 12mm Ratchet Center Punch Hammer Hand Drill with 5/16 Nut Driver C-Clamps (2)
Roof Rack Mounting Parts & Hardware Parts Clamp Bracket (4 ea.) Parts Rack Clamp (4 ea.) Rack Plate (4 ea.) 3/8 Flat Washer 3/8 Split Washer 3/8 Nut Rain Gutter Bracket (4 ea.) L-Bracket (4 ea.) 5/16 Cap Bolts Flange Bolts 5/16 Flat Washers Serrated Flange Nuts 5/16 Flat Washers 5/16 Split Washers 5/16 Nuts Hardware: 8 - M8X1.25X25mm! Flange Bolts 8 - M8X1.25!! Serrated Flange Nuts 8-10X32!! Self Drilling Screws 16!!! Rubber Washer Hardware: 8-5/16X18X3/4! Cap Bolts 8-5/16X18X3/4! Nuts 16-5/16!! Flat Washers 8-5/16!! Split Washers 4-3/8X16!! Nuts 4-3/8X16!! Flat Washers 4-3/8X16!! Split Washers
Roof Rack Parts & Hardware Roof Rack (Ships in two parts) 5/32 Allen Wrench Button Head Allen Screw Hardware: 1 ea.!! 5/16 Allen Wrench 2 ea.!! Button Head Allen Screws Self-drilling screws Rubber Washers Hardware: 8-10X32! Self Drilling Screws 16!! Rubber Washers Wind Fairing
Assembling the Roof Rack Protective Wrapping Step 1 Unpack the roof rack but leave the protective wrapping on. Step 2 Remove the (2) tube end caps. There is one on each half. Step 3 Align the two rack halves as shown. Step 4 Push the two halves together.
Adds 21 to overall length Tech Tip There is a roof rack extension available that can be added between the two halves to make a longer rack. Step 5 Locate, remove and open the package that contains the allen wrench and two screws. Tech Tip 5 The remainder of package contents will not be used with this application. They are used to attach the roof rack to many OEM (Original Equipment Manufacturers) roof racks. Put these items in safe place. You may need them in the future. Step 6 Lock the two rack halves together by installing the (2) screws.
Step 7 Tighten the (2) screws using the supplied 5/32 allen wrench. Assembling the Roof Rack Mounts Step 8 Install the L-Bracket in a bench vice. Note: Be sure to use a cloth (or other protection) so the mounts are not scratched or damaged. Step 9 Place the Rain Gutter Bracket on the L- Bracket as shown.
Step 10 Install the (2) supplied 5/16 bolts and flat washers as shown. Step 11 Install the (2) flat washers, split washers and nuts on to the bolts. Simply hand tighten the nuts for now. We will tighten them later. Step 12 Position the Clamp Bracket as shown. Step 13 Install the 3/8 flat washer, split washer and nut. Leave this nut loose for now.
Step 14 Repeat Steps 8 through 13 on the other 3 roof rack mounts. Attaching the Roof Rack Mounts to the Roof Rack Step 15 The 4 roof rack mounts will be installed in the four locations indicated by arrows. Note: These locations worked out well for our install. You could change the positioning of these mounts if desired. Step 16 Position the Flat Bracket on top of the front two bars.
Step 17 Position the Rack Clamp under the Flat Bracket and align the holes. Step 18 Position the L-Bracket on top of the Flat Bracket and align the holes. Step 19 Insert a supplied M8X1.25X25MM flange bolt from the bottom and install a M8X1.25 serrated nut on the bolt. Install the second bolt and nut the same way. Step 20 Repeat Steps 16 through 19 on the other (3) Rack Mounts. Note: Do not tighten these fasteners yet.
Installing the Wind Fairing Step 21 Carefully turn the roof rack over. Step 22 Remove the protective coverings. Step 23 Position and clamp the Wind Fairing and secure it using (2) C-clamps. Note: The Fairing should be centered side-to-side and top-to-bottom. Tech Tip 23.0 Insure that ALL the holes in the Wind Fairing align perfectly with the rack tubes. Note: This is important so that the self drilling screws can be centered on the tubing when they are installed. If the Wind Fairing holes are not centered on the tubes, the self-drilling screws will wander off to the side of the tube making the installation of the screws very difficult.
Wrong Positioning Correct Positioning Tech Tip 23.1 Double check the two end holes for correct positioning. Insure that they are not located in front of a welded joint. It may be necessary to raise or lower the fairing to avoid the welds. Tech Tip 23.2 This shows the correct positioning of the left end hole. Note: Installing a self drilling screw through a welded joint would be much more difficult than in the tube. Correct Positioning Tech Tip 23.3 This shows the correct positioning of the right end hole.
Note: Begin with the far left hole. Step 24 Using a center punch and hammer, make a dent perfectly centered in the hole of the fairing. Tech Tip 24 This shows the dent perfectly centered in the hole. Step 25 Place a supplied rubber washer behind the hole of the fairing as shown Step 26 Place a second rubber washer on a supplied 10X3/4 self drilling screw and position the screw against the dent in the tube.
Step 27 Using a drill with a 5/16 nut driver (or socket) drill the self drilling screw into the roof rack tube. Step 28 Repeat the previous step on the next hole as shown. Caution: Do not over tighten. The screw and the roof rack tube are easily stripped. Step 29 Install all (6) of the other self drilling screws and washers, working from left to right.
Installing the Roof Rack Step 30 Having an assistant help you, lift the roof rack into position. Position the roof rack front-to-back according to your own personal preference. We positioned ours about 8 rearward from the top of the windshield. Step 31 Once positioned front-to-back, position the gutter bracket in the rain gutter and the clamp bracket below the rain gutter. Position the other (3) roof mounts the same way. Step 32 Once all (4) roof mounts are positioned properly, tighten all (4) clamp brackets using a 9/16 ratcheting box end wrench or a socket. Torque spec is 13 ft. lbs. Caution: While tightening these clamps, observe the rain gutter. If the gutter bends or warps, stop tightening even if full torque has not been reached. Step 33 Once all the clamp brackets are tight, tighten the rain gutter bracket to L- Bracket bolts using a 1/2 socket and a 1/2 in box end wrench. Torque spec is 19 ft. lbs.
Bend in L-Bracket Bend in the Tube Step 34 Center the roof rack side-to-side. This can be done in several ways. You could have an assistant watch as you move it side to side or.... Step 34 Continued.... you could measure from the bend in the tube to the bend in the L- Bracket. Then move the rack side-toside until this measurement is equal in the other 3 locations. Step 35 Once the rack is centered side-to-side, tighten ALL (8) rack clamp bolts using a 12 mm box end wrench and a 12mm socket. Torque spec is 20 ft. lbs. Step 36 To insure you have not overlooked any fasteners, we recommend you check and tighten ALL the bolts and nuts one more time.
Congratulations!! You have successfully installed a roof rack. We hope these instructions have been helpful. If you have any suggestions about how we could improve our instructions or our products please email us at sales@lowrangeoffroad.com or call us at 801-805-6644.
As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at 801-805-6644 M-F 7:30am-5:30pm MST. Thank you for purchasing from Low Range Off-Road. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use. Revised 11/07/13 Copyright 2013 Low Range Off-Road, LC All Rights Reserved