Bestop Sunrider User manual

Installation Instructions
INSTALLATION TIME SKILL LEVEL
3 Hours 3 - Moderately Difficult
TOOLS
Vehicle Application
•Jeep TJ
2003 – 2006
Part Number: 51719
Sunrider®
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#2 T30
US Patents 5979968, 5765903

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 2
Tailgate Retainer Mount, Left,
Qty - 1, Part Number 311.85
Tailgate Retainer Mount, Right,
Qty - 1, Part Number 311.86
Rear Bow, Qty - 1,
Part Number 316.58
Door Surround - Left, Qty - 1,
Part Number 316.63 Door Surround - Right, Qty - 1,
Part Number 316.62
Center Bow, Qty - 1, Part
Number 316.55
Windshield Header Assembly,
Qty - 1, Part Number 386.44
Tailgate Bar, Qty - 1,
Part Number 288.75
Side Bow - Right,
Qty - 1, Part
Number 316.48
Side Bow - Left,
Qty - 1, Part
Number 316.49
Outboard Rear Bow
Bracket - Right, Qty - 1,
Part Number 315.70
Inboard Rear Bow
Bracket - Right, Qty - 1,
Part Number 315.68
Inboard Rear Bow
Bracket - Left, Qty - 1,
Part Number 315.69
Outboard Rear Bow
Bracket - Left, Qty - 1,
Part Number 315.71
Parts List and Hardware Identification
Top Fabric Qty - 1
Quarter Window, Right Qty - 1
Quarter Window, Left Qty - 1
Rear Window Qty - 1
Windshield Header Trim Qty - 1
Locktite Qty - 1

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 3
#8 x 1/2" Pan Head Washer
Screw - Black, Qty - 4, Part
Number 200.48
5/16-18 x 1" Phillips Head Bolt,
Qty - 2, Part Number 236.20
5/16-18 Tapping Plate, Qty - 2,
Part Number 200.50
5/16" Black Washer,
Qty - 2, Part
Number 233.04
10-32 Lock Nut, Qty - 10,
Part Number 316.94
Rear Bow Bracket
Bumpers, Qty - 2,
Part Number 315.74
Rear Door Surround
Bracket - Right, Qty - 1,
Part Number 315.66
Rear Door Surround
Bracket - Left, Qty - 1,
Part Number 315.67
Front Door Surround
Brackets, Qty - 2,
Part Number 315.75
Sun Roof Links, Qty - 2,
Part Number 315.59
Knobs, Qty - 4, Part
Number 316.85
Sleeves, Qty - 2,
Part Number 315.58
Main Pivot Bracket - Right,
Qty - 1, Part Number 386.47
Main Pivot Bracket - Left,
Qty - 1, Part Number 386.48
1/8" Allen Wrench, Qty - 1,
Part Number 276.68
10-32 Shoulder Bolt, Qty - 6,
Part Number 316.54
10-32 x 1.25 Screw, Qty - 2,
Part Number 316.93
10-32 x 1/2" Screw, Qty - 2,
Part Number 316.82
Bushing, Qty - 2,
Part Number 235.91
#10 Phillips Head Self Tapping Screw,
Qty - 8, Part Number 319.99
M6 Hex Screw, Qty - 4,
Part Number 322.41
#10 Star Washer, Qty - 8,
Part Number 317.58
J-Clip Strap, Qty - 1,
Part Number 321.71

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 4
When reinstalling Speak-
er Pods, be careful not to
pinch the wires between
the edge of the Speaker Pod and the Sport Bar.
If your vehicle has a cover over the Center Sport
Bar, unzip the cover to access the bar.
Locate the Main Pivot Brackets in the parts kit.
Orient the brackets with the tab toward the top and
the rear of the vehicle. Align the holes in the bracket
with the holes in the bar and install the bracket us-
ing two M6 Hex Screws for each bracket.
Stretch the cover around the bar and slip the open-
ings in the cover over the tabs on the Main Pivot
Brackets. Zip the cover closed.
Sport Bar
Cover Main Pivot Bracket
M6 Hex
Screws
These M6 screws have special threads
which will self-tap into non-threaded
holes as well as provide a tight, vibration resistant
attachment in pre-threaded holes.
Install Main Pivot Brackets
Locate the parts of the Right and Left Rear Bow
Brackets in the parts kit. Each bracket has two
pieces which are stamped R (right) and L (left).
Match rights and lefts.
If your vehicle has a cover over the Rear Sport Bar
Legs, unzip the cover to access the bar.
You will have to slip the parts of the Rear Bow
Brackets between the impact foam and the rear
sport bars. To do this, slip the Inboard half of the
bracket under the foam and around the sport bar
until the slot in the rear of the bracket is exposed
on the opposite side. Hook the tab on the Outboard
half into the slot and rotate the two pieces into posi-
tion so that the tab on the bracket hooks into the
rear opening of the seat belt cylinder.
If you have a Sport Bar Cover, wrap the cover
around the bar and mark the location of the tabs on
the Rear Bow Brackets. Cut openings in the cover
for the tabs. Slip the new openings in the cover
over the metal tabs and zip the cover closed.
Locate the Rear Bow Bracket Bumpers in the parts
kit and slip them over the two top tabs in each
bracket. Install a 10-32 x 1/2" Screw and a 10-32
Lock Nut through the bumpers and bracket.
Install Rear Bow Brackets
Use pliers to squeeze the top tabs, if
necessary, to align the holes and im-
prove ease of installation of the Bracket Bumpers.
Rear Sport Bar
Rear Seat Belt
Cylinder Opening
Rear Bow
Bracket
10-32 x 1/2"
Screw Outside
Driver's Side Shown
Rear Bow
Bracket Bumper
10-32 Lock
Nut
Hook tab on Outboard
half into slot in Inboard
half
Outboard
Inboard
Impact Foam
Impact Foam
Slide Bracket under
Impact Foam

Sunrider®– Installation Instructions
Rev. D 1208 51719 pg. 5
Locate the Left and Right Door Surrounds, the Front
Door Surround Brackets and the Left and Right Rear
Door Surround Brackets in the parts kit.
Place the holes in the Front Door Surround Brackets
over the front pair of holes on each Door Surround,
farthest from the bend. Orient the brackets with the
long tab toward the inside and with the threaded
rivet up. Install the brackets using two #10 Phillips
Head Self Tapping Screws and two #10 Star Wash-
ers for each bracket.
Orient the Rear Door Surround Brackets with the
Spring Plunger toward the inside and to the front of
the Door Surround. Align the holes in the brackets
with the second pair of holes in the Door Surrounds
and install them using two #10 Phillips Head Self
Tapping Screws, two #10 Star Washers and Loctite
for each bracket.
Front
Toward
Front
Door Surround
Rear Door
Surround Bracket
Spring Plunger to inside
and front of Door Surround
#10 Phillips Head Self Tapping Screws (apply
Loctite to the threads) and #10 Star Washers
#10 Phillips Head Self Tapping
Screws (apply Loctite to the
threads) and #10 Star Washers
Front Door
Surround Bracket
Door Surround Door Surround -
Driver’s Side Shown
Assemble Door Surrounds
and Front and Rear Door
Surround Brackets
Horizontal Support
Bar
Knob
Rear Door Surround
Bracket from Top Door Surround
Rear Door
Surround Bracket
Orient the Left and Right Door Surround Assem-
blies on the vehicle with the brackets toward the
inside. Insert the nipples in the brackets into the
holes in the bottom of the Horizontal Support Bar.
Thread a Knob from the parts kit through the top
of the Horizontal Support Bar and into each of
the Door Surround Brackets. Close the door to
check the seal and adjust the Front Door Surround
Bracket if necessary for a good seal.
Knob
Detail of
Knobs
Door Surround Bracket -
Front or Rear
Horizontal
Support Bar
Thread Knob
into Bracket
Front Door Surround
Bracket
Horizontal
Support Bar
Door Surround
Front Door Surround
Bracket from Bottom
Install Door Surround
Assemblies