Bestop Sport bar covers User manual

InstallationInstructions

INSTALLATION TIME SKILL LEVEL

1 Hour 1 - Easy

TOOLS

Vehicle Application

•Jeep TJ Wrangler

2003 -2006

Part Number: 80022

Sport Bar Covers

Socket

DO NOT remove seat belts for installation.

Manufacturer’s warranty will be compromised.

sport bar covers

•Jeep TJD Wrangler Unlimited

2004 -2006

Part Number: 80023

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Sport Bar Covers - Installation Instructions

Rev. B 1106 80022 / 80023 pg. 2

Parts List

Sport Bar Cover Qty - 1

Horizontal Sport Bar Covers Qty - 2

Use the #30 Torx to remove the bolts on the speaker pods.

Pull the pods out slightly to expose the wiring inside. Release

these wires by lifting up the tab on the connector. The speaker

pods can be removed and set aside for later.

Remove #30 Torx Bolts

If your vehicle has sport bar

covers, you must cut them

off before beginning this

installation. The casing

around the front seat belts

can be pulled out slightly to

remove the fabric under it.

If your vehicle has a soft top, release the top

from the windshield and lay the top and bows

down on the tailgate.

Use a T-30 Torx driver to remove the Pivot

Knuckle Screws that attach the Side Bow and

Rear Bows to the brackets on each side of the

vehicle. Push down on each bow to pop it loose

from the bracket.

Leave the bows and fabric laying on the tailgate.

Driver's Side Shown

Side Bow

Pivot Knuckle

Rear Bow

Pivot Knuckle

Remove Pivot

Knuckle Screws

Front

The installation of the Sport Bar Covers will be

easier if the door molding is removed. To remove

the door molding, unscrew the knobs above the

door opening and lift the molding off of the vehicle.

Door Molding

Knobs

Lower Soft Top

Remove Speaker Pods

Tab

Connector

Pod

Remove Existing

Sport Bar Covers

Front seat

belt casing

Remove Door Molding

Sport Bar Covers - Installation Instructions

Rev. B 1106 80022 / 80023 pg. 3

Install Sport Bar Cover to Center Bar

Locate the two sets openings on the center bar.

The ones closer to the center will expose the

holes for the speaker pod’s rod and the

outer two holes are for it’s wiring. Pull the

wires through the outer holes. Zip the

fabric assembly around the center bar.

Outer Hole

Pull wire

through hole

View from Driver’s Side

Inner Hole

Front Horizontal

Bar

Center Bar

Install Sport Bar Cover

to Sides

6Expose Pivot Brackets

Orient the entire fabric assembly over the Vehicle’s Sport Bars with the zippers towards the

underside of the bars. The Bestop ® label should be on the rear leg of the passenger’s side

and there should be some pre-cut openings for the seat belts and the speaker pods.

Wrap fabric assembly around the sides tucking the

fabric under the front seat belt casings. The larger

pre-cut holes should be position around the clamps

under the casing. The clamps mst be exposed to

secure the seat belt casing.

Tuck Fabric Under

Seat Belt Casing

Pull Casing Away

from Bar

Pre-Cut

Holes

Clamps

Seat Belt

Mounts Here

Back

Front

View from Outside Passenger’s

Side - with the Seat Belt and Casing

Removed.

Pivot Bracket

Flanges Seat Belt

Front

View from Outside

Passenger Side of TJ Wrangler

If you have a soft top, insert the Pivot Bracket Flanges

through the slits in the fabric. The TJ Wrangler (’03-’06)

has two Flanges and the TJD Wrangler Unlimited (’04-’06)

has only one.

Sport Bar Covers - Installation Instructions

Rev. B 1106 80022 / 80023 pg. 4

Snap Flap

Install Sport Bar Cover

to Rear Legs

Position & Zip Upper Leg

Rear Sport Bar

Cover

View from Outside

Passenger Side

Rear

Drape the cover over the Rear Sport Bar and

Fit the curve in the fabric over the curve of the

bar. There will be a pre-cut hole for the seat

belt, hook the hole of the fabric around the seat

belt mount. Zip up the lower portion of the cover

and start to zip the upper portion. The start and

end of the two zippers can be tucked behind the

seat belt mount.

Rear Sport

Bar Cover

Center Sport

Bar Cover

Zip Upper Portion

View from Outside

Passenger Side

Rear

Start Upper Zipper

Seat Belt

Lower Zipper

Continue to zip the upper portion of the rear leg towards the

front. Before you tighten the fabric with the zipper, position the

pre-cut holes over the speaker pod holes on the sport bar.

Pre-cut Holes Over

Speaker Pod Holes

The zippers for the center, side and rear bar

should all intersect above the front seat belts.

Pull the flap over from the side and snap it to

the fabric assembly.

Front

View from Inside

Passenger Side

Side Zipper

Stops Here

Rear Zipper

Stops Here

Center Sport Bar

Center Zipper

Snap Flap to Side

Snap Flap to

Center Bar

11 Secure Front Seat Belt

Casing

Front seat

belt casing

After the flap is snapped and the fabric is

adjusted around the seat belt mount, secure

the Seat Belt Casing. Press the panel down

into the clamps underneath.

The Clamps should be exposed and

free from fabric coverage.

NOTE

Side Flap

Sport Bar Covers - Installation Instructions

Rev. B 1106 80022 / 80023 pg. 5

12 Re-Install Speaker Pods

Install Horizontal Bar Cover

Re-Install the Speaker Pods onto the new Sport Bar Cover. The pre-cut holes should

expose placement of the speaker rod and wiring on the center bar, and placement of

the bolts on the upper leg. Re-connect the wiring and tighten the bolts down again with

the #30 Torx.

Re-connect Wiring

Bolt Speaker

Down

Speaker Pods Should cover

pre-cut holes completely

NOTE

Locate a Horizontal Bar Cover in the parts kit and orient it with the openings in the cover over the mounting holes for the Door Surround. Wrap the cover

around the bar and close the zipper from front to back. Slide the cover around the bar so that the zipper is along the inside of the bar and the openings

are clear to accept the Door Surround.

Repeat this procedure on the other side of the vehicle.

Close Zipper

from Front to Back

Slide Cover so zipper

is along inside of

Horizontal Bar

Rear

View from Inside Passenger Side

Front

View from Outside

Passenger Side