Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
123
Repair and Service Manual
655827
WEATHER PROTECTION
SUN TOP AND WINDSHIELD
The top does not provide protec-
tion from roll over or falling
objects.
The windshield does not provide protection from tree
limbs or flying objects.
The top and windshield are designed for weather protec-
tion only.
Clean with water and a clean cloth. Minor scratches may
be removed using a commercial plastic polish or Plexus
plastic cleaner available from Service Parts.
Transporting Vehicle
To reduce the possibility of severe
injury or death while transporting
vehicle:
Secure the vehicle and contents.
Never ride on vehicle being transported.
Always remove windshield before transporting
vehicle.
Maximum speed with sun top installed is 50 mph
(80 kph).
If the vehicle is to be transported at highway speeds, the
sun top must be removed and the seat bottom secured.
When transporting vehicle below highway speeds, check
for tightness of hardware and cracks in sun top at mount-
ing points. Always remove windshield when transporting.
Always check that the vehicle and contents are ade-
quately secured before transporting. The rated capacity
of the trailer or truck must exceed the weight of the vehi-
cle (see GENERAL SPECIFICATIONS for vehicle
weight) and load. Lock the park brake and secure the
vehicle using ratchet tie downs.
SUN TOP
Tool List Qty.
Plastic faced mallet......................................................1
Wrench, 1/2" ................................................................2
Wrench, 9/16" ..............................................................2
Hex wrench, 7/32" .......................................................1
Straight blade screwdriver ...........................................1
Rear Struts Installation
1. Using a plastic faced hammer, tap end caps (5) into
the top of the rear struts (3, 4) (Ref. Fig. 1) (See
Detail B and D).
2. Place washer (7) onto bolt (6) and insert bolt
through the top hole in the seat back support (3 - 4
threads). Place the teflon washer (8) on the end of
the bolt. This teflon washer is needed to prevent
squeaking.
3. Insert rear strut (3) through the square hole in the
top of the seat back support and push the bolt
through the top hole in the rear strut.
4. Place washer (7) and lock nut (9) on the end of the
bolt just enough to prevent the bolt from falling out.
5. At the lower hole, slide a teflon washer (8) between
rear strut and seat back support and align holes.
6. Insert bolt (6) with washer (7) through lower hole
and secure with washer (7) and lock nut (9).
7. Finger tighten hardware to allow for adjustment.
8. Repeat procedure with rear strut (4) at passenger
side of vehicle.
Front Strut Installation
1. Remove and discard the four bolts from the front
cowl (See Detail A).
2. At the upper hole (both sides of vehicle), install the
front strut (2) with bolt (15) and lock washer (14) on
the outside of strut, a spacer (13) and a washer (12)
between the front cowl and strut.
3. Finger tighten hardware to allow for adjustment.
4. At the lower hole, secure the strut with bolt (15) and
lock washer (14) on the outside of strut, and two
washers (12) between the front cowl and strut as
shown.
5. Finger tighten hardware to allow for adjustment.
Sun Top Installation
1. Place sun top onto struts.
2. At front of vehicle, secure sun top loosely with bolts
(11), washers (18), spacers (20), washers (18) and
lock nuts (19).
3. Finger tighten hardware to allow for adjustment (See
Detail C).
4. At rear of vehicle, insert bolts (10), washers (18),
spacers (20), washers (18) and lock nuts (19) (See
Detail D).
5. Tighten all hardware to 13 - 15 ft. lbs. (18 - 20 Nm)
torque.
ITEM NO TORQUE SPECIFICATION
6, 10, 11, 15 13 - 15 ft. lbs. (18 - 20 Nm)
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