Bestop Supertop User manual

Installation Instructions
INSTALLATION TIME SKILL LEVEL
3 Hours 3 - Moderately Difficult
TOOLS
Vehicle Application
•Jeep CJ7
1976 – 1986
Hard Door Models
Part Number: 51599
Supertop®
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1/8", 5/32",
7/32" and 3/8" #20, #40 and
#45
10'
•Jeep Wrangler/YJ
1986 – 1995
Hard Door Models
Part Number: 51599

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 2
Parts List and
Hardware Identification
Top Fabric Qty - 1
Quarter Window, Right Qty - 1
Quarter Window, Left Qty - 1
Rear Window Qty - 1
#8 x 1/2" Pan Head Washer
Screw - Black, Qty - 13, Part
Number 200.48
5/16-18 x 1" Phillips Head Bolt,
Qty - 16, Part Number 236.20
5/16-18 Tapping Plate, Qty - 16,
Part Number 200.50
5/16" Black Washer,
Qty - 16, Part Num-
ber 233.04
Windshield Retainer - Right,
Qty - 1, Part Number 225.42
Windshield Retainer - Left,
Qty - 1, Part Number 225.43
#10 x 1/2" Pan Head Sheet
Metal Screw, Qty - 4, Part
Number 1.92
Corner Belt Rail, Right, Qty - 1,
Part Number 288.33
Corner Belt Rail, Left, Qty - 1,
Part Number 288.34
Bow Assembly - Right,
Qty - 1, Part Number
246.56
Bow Assembly - Left,
Qty - 1, Part Number
246.57
Vertical Retainer Mount, Left,
Qty - 1, Part Number 229.25
Vertical Retainer Mount, Right,
Qty - 1, Part Number 229.24
Windshield Bracket - Right,
Qty - 1, Part Number 137.96
Windshield Bracket - Left,
Qty - 1, Part Number 137.97
Tailgate Bar, Qty - 1,
Part Number 288.75
Side Belt Rail - Right, Qty - 1,
Part Number 225.04
Side Belt Rail - Left, Qty - 1,
Part Number 225.05

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 3
CJ7 Windshield Adjustment: If
necessary, loosen the two screws
in the Windshield Clamps at the
base of the windshield on each side
of the vehicle. Adjust the windshield
forward or back, use a shim if
needed to position the windshield,
and tighten the screws.
Windshield
Clamp Detail
Front
Measurement Detail
Top lip of
windshield
Tape
Measure
75 1/8"
Rear point of
measurement
on body
Adjusting Screws -
Some Models may
require a #40 Torx
CJ7 Windshield Measurement
Improper windshield
adjustment will result
in poor fitting top and
doors, causing looseness or undue strain on the
top.
#10 x 1/2" Pan Head
Sheet Metal Screws
Sun Visor
Mount -
#20 Torx
Bolt
Windshield
Bracket
After adjusting the windshield, install the Wind-
shield Brackets. If present remove the outboard
sun visor fasteners on both sides of the windshield
frame. Place the Windshield Brackets flush with
the frame on the upper corners of the windshield.
Use the bracket as a template to mark, center
punch and drill two 5/32" holes for each bracket.
Mount each bracket to the windshield frame using
two #10 x 1/2" Pan Head Sheet Metal Screws.
Reinstall sun visor brackets.
Install Windshield Brackets –
CJ7 Only
Ifyouarereplacinganoldsofttop,becertain
that all parts of the old top are removed,
including the windshield retainer. Old metal parts are
not compatible with the new Supertop. Using parts
other than those provided in your Supertop kit can
result in personal injury and/or damage to the vehicle
and soft top.
Before installing the top, check the windshield
measurement. The distance from the top lip of the
windshield to the top outer edge of the body must
be 75 1/8" on both sides of the vehicle. Measure
from 6" inside the doors.

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 4
Wrangler Windshield Measurement
Improper windshield
adjustment will result
in poor fitting top and
doors, causing looseness or undue strain on the top. Install Windshield Brackets –
Wrangler/YJ Only
Under most circumstances, the wind-
shield of the Wrangler will not require
any adjustment. If your Wrangler windshield should
require adjustment, this adjustment should be per-
formed only by an authorized automotive mechanic
using a special "Tamper-Proof" Torx head tool.
#40 TORX Bolts
#45 TORX Bolt
Wrangler/YJ Windshield
Adjustment: If necessary,
loosen the #40 TORX bolts
in the windshield clamps to
loosen the windshield in order
to slip the bracket under the
horizontal tube.
Reinstall the bolts that
secure the Horizontal
Sport Bars to the wind-
shield with a torque of 17.0 ft. lbs. each. If you do not
haveatorquewrenchtheseboltsshouldbetestedby
a qualified mechanic using a torque wrench. Failure
totighten andtest thetorque ofthese boltscan result
in personal injury or loss of life to the driver and oc-
cupants of the vehicle in the event of an accident.
75 1/8"
Before installing the top, check the windshield
measurement. The distance from the top lip of the
windshield to the top outer edge of the body must be
75 1/8" on both sides of the vehicle. Measure 4"-6"
inside the doors.
Front Measurement
Detail
Top lip of
windshield Tape
Measure
Rear point of
measurement
on body
Use a #20 Torx to remove the outboard sun visor
fasteners on both sides of the windshield frame.
Remove the two #40 Torx head bolts that secure
the horizontal sport bar to the windshield frame.
Slide the Windshield Brackets between the wind-
shield and the horizontal sport bar mounts.
Reinstall the Torx head bolts, starting each in the
frame with your fingers. After the Torx head bolts
are started by hand tighten with your rachet and
Torx drive tool. Do not lay this tool aside until both
bolts are completely tightened. If you tighten one of
these bolts and the telephone rings - LET IT RING.
NEVER LAY THIS TOOLASIDE OR INTERUPT
THIS PROCEDURE. This procedure should be fol-
lowed carefully on both sides of the vehicle.
Windshield
Sun Visor
Sun Visor Mount
- #20 Torx bolt
Remove #40 TORX Bolts
Horizontal
Sport Bar
Windshield
Bracket Slide Windshield
Bracket between
Windshield and
the Sport Bar
Mount

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 5
A loose Windshield Re-
tainer may allow the top
to disengage from the
windshield, causing damage to the top and possible
injury to the occupants of the vehicle.
Make certain that the Windshield Retainer is se-
curely fastened to the windshield during installation
and at all other times by checking the tightness of
the mounting screws every three months.
Do not use any drill size other than 1/8". Failure
to use the correct size may cause the Windshield
Retainer to loosen.
Install Windshield Retainer
Position the two piece Windshield Retainer on
top of windshield frame. Use retainer pieces as
templates to mark, center punch and drill eleven
1/8" holes. Install with eleven #8 x 1/2" Pan Head
Screws.
Windshield
Windshield Retainer
(2 pieces)
Use retainer pieces
as guide to drill holes.
Install retainer pieces
with #8 x 1/2" Phillips
Head Screws
Windshield
Frame
Front
Windshield
Retainer
#8 x 1/2"
Pan Head
Screw
Drill 1 hole
between the
two retainer
pieces
Windshield
Retainer Detail
Cross Section
Install the Left and Right Side Belt Rails on each
side of the vehicle. Use the Belt Rails as templates
to mark, center punch and drill six 3/8" holes along
the top edge of the body on each side of the vehicle.
Secure the two rear holes in the rails with two 5/16"
Phillips Head Bolts, two 5/16" Washers and two
5/16" Tapping Plates. Do not tighten the bolts yet.
Install Side Belt Rails
When drilling in the top
edge of the vehicle body,
check underneath for
wiring for the rear lights. Pull the wiring out of the
way before drilling.
Tapping Plate
Detail
Tapping
Plate
Corner
Belt Rail
5/16" Phillips
Head Bolt
Vehicle
Body
5/16" Washer
Side Belt
Rail
5/16" Phillips
Head Bolt
Side Belt
Rail
Inside of Vehicle
5/16" Phillips
Head Bolt and
5/16" Washer
Side Belt Rail Detail
Cross Section
Sport
Bar
Sport
Bar
Front
Tapping
Plate
Body Panel

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 6
Install Rear Corner Belt Rails
When drilling in the top
edge of the vehicle body,
check underneath for
wiring for the rear lights. Pull the wiring out of the
way before drilling.
Tapping Plate
Detail
Tapping
Plate
Corner
Belt Rail
5/16" Phillips
Head Bolt
Vehicle
Body
5/16" Washer
Install Vertical Retainer
Mounts
Tapping Plate
Detail
Tapping
Plate
Vertical
Retainer
Mount
Side Belt
Rail
5/16" Phillips
Head Bolt
5/16" Washer
Vehicle Body
There may be a small gap of
+/- 1/4" between the Corner Belt
Rails and the Side Belt Rails.
Install the Left and Right Rear Corner Belt Rails on
each side of the vehicle. Notice that the Corner
Belt Rails do not butt-up against the Side Belt Rails
installed in Step 3, this is normal. Use the Corner
Belt Rails as templates to mark, center punch and
drill two 3/8" holes in the top edge of the vehicle
body. Some vehicles may already have some of
these holes. Install the Corner Belt Rails with two
5/16" Phillips Head Bolts, two 5/16" Washers and
two 5/16" Tapping Plates. At the location of the
remaining hole in the Corner Belt Rail, next to the
tailgate, mark, center punch and drill a 1/8" hole.
Install a #8 x 1/2" Pan Head Screw. Do not tighten
the bolts yet.
Rear Corner
Belt Rail
Tapping
Plate Inside of
Vehicle
Body
Panel
Rear Corner Belt Rail
Detail Cross Section
Rear Corner
Belt Rail
Sport
Bar
5/16" Phillips
Head Bolts
5/16" Phillips
Head Bolt and
5/16" Washer
Screw
Install the Vertical Retainer Mounts on top of the
Side Belt Rails, just behind the door openings.
Secure them in place with two 5/16-18 x 1" Phillips
Head Bolts, two 5/16" Washers and two 5/16" Tap-
ping Plates. Do not tighten the bolts yet.
Vertical Retainer
Mount
Side Belt Rail
Sport Bar

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 7
Install Bow Assembly
Lay the bow halves on top of the body with the
holes in the Bow Mounts over the third and fourth
holes in the Side Belt Rails.
It is important that the white packaging tape
remain on the bow assemblies until the forward
bolt is tightened on both sides.
Secure the FRONT hole in the Bow Mount with a
5/16-18 x 1" Phillips Head Bolt, a 5/16" Washer and
a 5/16" Tapping Plate. Once the front hole is secure,
cut the packing tape.
Start the male end of the Top (Front) Bow into the
female end. Push forward on the bow until the two
sides snap together. Slide the foam pieces on the
bow together.
Once the Bow Mounts are secure, tighten all of
the bolts on the Belt Rails.
Leave packing tape on Bow
Assemblies until front holes
of Bow Mounts are secure
Bow
Front
Side Belt Rail
Bow
Mount
Secure front hole
first - inside mount
5/16-18 x 1"
Phillips Head
Bolt and 5/16
Washer
5/16 Tapping Plate -
under ledge
Tapping Plate
Detail
Tapping
Plate
Side
Belt Rail
5/16" Phillips
Head Bolt
Vehicle
Body
Bow
Mount
Push Bow Ends Together

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 8
Install Bow Assembly
Bow
Front
Side Belt
Rail
Bow
Mount
5/16-18 x 1"
Phillips Head
Bolt and 5/16
Washer
5/16 Tapping Plate -
under ledge
Release the small metal rods from the plastic clips
on both sides of the vehicle.
Lift the Top (Front) Bow and start the male end
of the Bottom (Rear) Bow into the female end.
Push forward on the bow until the two sides snap
together.
Slide the Bottom (Rear) Bow up on the Top (Front)
Bow to access the rear bolt position in the Bow
Mount. Install and tighten the rear bolt in the Bow
Mount on both sides of the vehicle.
Raise the Top (Front) Bow Assembly, holding the
small rods in an upright position, and insert the
Vertical Rods into the hole in the Vertical Retainer
Mount. Attach the Horizontal Rod to the Windshield
Bracket using the Bailhead Stud. The pin on the
Bailhead Stud will only turn clockwise because of
the prongs on the edges of the opening in the Wind-
shield Bracket. Slip the pin through the opening and
turn the Bailhead Stud a quarter turn clockwise so
that the flanges on the pin are secure between the
prongs.
Push Bow Ends Together
Vertical
Rod
Front
Vertical Retainer
Mount
Outside of Vehicle
Vertical
Rod
Windshield
Bracket Horizontal
Rod
Turn Bailhead Stud 1/4 turn
clockwise to secure in place
Sport Bar
Windshield
Bracket Horizontal
Rod
Turn Bailhead
Stud 1/4 turn
clockwise so pin
catches between
prongs on bracket
Horizontal
Rod

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 9
Install Top on Vehicle
Snap Top to Rear Bow
Secure Rear Corners
Locate the top and orient it on the vehicle. Drape
the top over the bows and insert the plastic strip
sewn along the front of the top into windshield
retainer attached on the front of the windshield
frame. Center the front of the deck on the vehicle
so that it is an equal distance from the top of the
windshield flange on both sides.
If the snaps don't appear to line up,
push the rear bow forward to relieve
the pressure on the bow. This will allow the snaps
to line up more easily.
Windshield Driver's Side of Vehicle
Make sure space between top
fabric and windshield flange is
equal on both sides
For best possible installation, check to
make sure that the soft top is perfectly
centered on the vehicle.
View from inside top
Snap to bow
Bow
Snap the flaps to the six studs on the rear bow.
Plastic Strip Fabric
Windshield
Retainer
Make sure that
only Plastic Strip
is in retainer
Black Plastic
Strip
Rear Corner
Retainer
Fabric
Insert the black plastic strips at rear corners of top
into Corner Belt Rails. There is a plastic reinforce-
ment sewn into the corner of the top, in addition to
the plastic strip.
Make sure that the reinforcement is not caught
under the Corner Belt Rail.
Plastic
Reinforcement

Supertop®– Installation Instructions
Rev. G 0312 51599 pg. 10
Raise the Rear Bow
Slide the Rear Bow up on the Front Bow and insert
the small bent tab into one of the four holes in the
Front Bow.
Rear
Bow
Front
Bow
If the top is extremely tight, slip the tab
into the bottom hole. The top will loosen
up after a few hours in the sun. Then the tab may
be inserted into a higher hole position.
Insert tab
into one
of the four
holes
Do not use
this hole!!
Start top and rear zippers on side curtain 6 inches.
If necessary, release the Bow Coupler and
slide the top around the Corner Belt Rail
towards the window to make it easier to start the zip-
pers on the Side Curtains.
Install Side Curtain
Slip the plastic strip on the bottom of the side cur-
tain into the side retainer. Close the top zipper on
the side curtain.
Secure Bottom of Side Curtain
Start top and
rear zippers
Zipper under flaps
Side
Curtain
Side
Retainer
Fabric
Plastic
Strip
Start at one end
of the strip and
work along it to
the other end.
Close
Zippers