SEB-RRTT_Suzuki Samurai Roof Rack Kit for Hard Top, Tin Top by

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
Parts
Rain Gutter
Bracket (4 ea.)
Rack Plate
(4 ea.)
Rack
Clamp
(4 ea.)
Clamp Bracket
(4 ea.)
3/8 Flat Washer
3/8 Split Washer
L-Bracket
(4 ea.)
3/8 Nut
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:
Hardware:
8 - M8X1.25X25mm!
8 - M8X1.25 ! !
8 - 10X32!
!
16 !
!
!
Flange Bolts
Serrated Flange Nuts
Self Drilling Screws
Rubber Washer
8 - 5/16X18X3/4!
8 - 5/16X18X3/4!
16 - 5/16 !
!
8 - 5/16 !
!
4 - 3/8X16!
!
4 - 3/8X16!
!
4 - 3/8X16!
!
Cap Bolts
Nuts
Flat Washers
Split Washers
Nuts
Flat Washers
Split Washers
Roof Rack Parts & Hardware
Roof Rack
5/32 Allen Wrench
Button Head
Allen Screw
(Ships in two parts)
Hardware:
1 ea. !
2 ea. !
!
!
5/16 Allen Wrench
Button Head Allen Screws
Self-drilling screws
Rubber Washers
Wind
Fairing
Hardware:
8-10X32 !
16 !
!
Self Drilling Screws
Rubber Washers
Assembling the Roof Rack
Protective
Wrapping
Step 1
Step 2
Unpack the roof rack but leave the
protective wrapping on.
Remove the (2) tube end caps. There is
one on each half.
Step 3
Step 4
Align the two rack halves as shown.
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.
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 5
Locate, remove and open the package
that contains the allen wrench and two
screws.
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
Step 9
Install the L-Bracket in a bench vice.
Place the Rain Gutter Bracket on the LBracket as shown.
Note: Be sure to use a cloth (or other
protection) so the mounts are not
scratched or damaged.
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
Step 13
Position the Clamp Bracket as shown.
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
Step 20
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.
Repeat Steps 16 through 19 on the
other (3) Rack Mounts.
Note: Do not tighten these fasteners yet.
Installing the Wind Fairing
Step 21
Step 22
Carefully turn the roof rack over.
Remove the protective coverings.
Step 23
Tech Tip 23.0
Position and clamp the Wind Fairing and
secure it using (2) C-clamps.
Insure that ALL the holes in the Wind
Fairing align perfectly with the rack
tubes.
Note: The Fairing should be centered
side-to-side and top-to-bottom.
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
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.
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.
Correct
Positioning
Tech Tip 23.2
This shows the correct positioning of the
left end hole.
Note: Begin with the far left hole.
Step 24
Tech Tip 24
Using a center punch and hammer,
make a dent perfectly centered in the
hole of the fairing.
This shows the dent perfectly centered
in the hole.
Step 25
Step 26
Place a supplied rubber washer behind
the hole of the fairing as shown
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
Step 28
Using a drill with a 5/16 nut driver (or
socket) drill the self drilling screw into
the roof rack tube.
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
Step 31
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.
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
Step 33
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.
Once all the clamp brackets are tight,
tighten the rain gutter bracket to LBracket bolts using a 1/2” socket and a
1/2 in box end wrench. Torque spec is
19 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.
Bend in
L-Bracket
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 . . . .
Bend in
the Tube
Step 34 Continued
. . . . you could measure from the
bend in the tube to the bend in the LBracket. Then move the rack side-toside until this measurement is equal in
the other 3 locations.
Step 35
Step 36
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.
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
[email protected] 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