Pavement Ends 41530 User Manual

Header Sun Cap Plus

Installation Instructions

For: Wrangler 1997 - 2002 Part Number: 41530

To be used with or without Soundbar

To be used with or without Door Surround Side Rails

Important Note: Must be used with a TJ Header Windshield Channel Kit, Part Number 51238-01.

WARNING

This product is designed to enhance the appearance of the vehicle
and to shield the occupants from ordinary weather conditions.
Do not rely in any way on the components of this product to
contain occupants within the vehicle, or to protect against injury
or death in the event of an accident. This top will not protect the
occupants from falling objects. Never operate vehicle in excess
of manufacturer’s specifi cations.

WEAR SEAT BELTS AT ALL TIMES

Read and follow, precisely, all installation instructions provided
when installing top. Failure to do so may result in a poor fi tting
top and could place occupants of the vehicle in a potentially
dangerous situation. After installing or reinstalling the top, check
to make sure it has been properly installed.

41530 pg 1

Installation Tips

After completing the installation, keep these instructions
for future reference. Before you begin installing this
product, read all instructions thoroughly. Below are a
few tips to make this installation easier.

For a smooth fi t:

For ease in installation, this product should be installed
at temperatures above 72° F. Below this temperature,
the fabric may contract an inch or more, making it dif­fi cult to fi t to the vehicle.

It is normal for the fabric to contract and wrinkle when
stored in the shipping carton. Within a few days after
the installation, the fabric will relax and the wrinkles will
disappear.

Rev. B 1210

Sun Cap Plus Qty - 1

Step One

Orient the Sun Cap Plus on the vehicle and drape it over the bows. Insert the
plastic strip sewn along the front of the Sun Cap Plus into the windshield
channel. Do not catch the fabric in the channel. Center the Sun Cap Plus on the
vehicle so that it is an equal distance from the top of the windshield fl ange on
both sides.

Parts List

Make sure that only Plastic
Strip is in channel

Windshield

Plastic Strip

Make sure space between top fabric
and windshield fl ange is equal on
both sides

Fabric

Windshield Channel

Driver's Side of Vehicle

Note: For best possible installation, check to
make sure that the top is perfectly centered
on the vehicle.

View from front

Step Two - Without Soundbar

Drape the fabric over the sport bar. Make sure that the center
strap is behind the center sport bar, and that the side straps and
buckles hang off the side.

Wrap the long center strap, inside the Sun Cap Plus around the
sport bar, pull the strap forward to the windshield. Then pull the
end of the strap back and thread it through the buckle. Tighten it
securely.

Strap and Buckle
hang off side

41530 pg 2

Threading Strap
through Buckle

Footman Loop

Buckle

Strap

Center Strap - Thread
through Footman Loop

Rev. B 1210

Step Two - With Soundbar

Drape the fabric over the sport bar. Make sure that the web strap and buckle on the sides of the Sun
Cap Plus are on the outside, and that the long center strap is resting on top of the soundbar.

Push the end of the center strap between the sport bar and the soundbar. Push the end of the strap
through until you can get ahold of the strap to pull the buckle through. Wrap the center strap inside
the Sun Cap Plus around the sport bar, pull the strap forward to the windshield. Thread the strap
through the footman loop on the windshield frame. Then pull the end of the strap back and thread
it through the buckle. Tighten it securely.

Note: Some soundbars fi t extremely tight against the
sport bar preventing the buckles easy access to the
straps. If this is the case, the soundbar must be moved
slightly rearward. The distance will vary on each
vehicle.

Soundbar

Strap Between Sport
Bar and Sound Bar

Strap and Buckle
hang off side

Footman Loop

Center Strap - Thread
through Footman Loop

Threading Strap
through Buckle

Remove the four bolts securing the soundbar in place.
Reposition the soundbar rearward (check the clearance
for buckle accessibility), notch out the soundbar attach­ment brackets accordingly - in most cases it will be less
than 1/4". Reinstall the four bolts.

Buckle

Strap

Step Three

Locate the hook and loop strips sewn to each side of the Sun Cap
Plus. Fasten the strips to each other as you wrap them around the
front sport bars.

41530 pg 3

Wrap straps around bar and fasten
Hook and Loop to each other.

Rev. B 1210

Step Four

Wrap the strap sewn to the side of the Sun Cap Plus
around the sport bar and thread it through the buckle
on the other side of the bar.

Strap

Threading Strap
through Buckle

Buckle

Strap

Rear

Wrap Strap around Sport Bar

Buckle

View from outside vehicle

and under Seat Belt Mount

Rear Sport Bar

Step Five

Locate the Buckles and straps sewn to the rear corners of the sun Cap Plus.
Wrap the straps around the sport bars and under the seat belt mounts.
Thread the ends of the straps through the buckles and pull them tight.

41530 pg 4

View from inside vehicle - look­ing toward rear

Rear Sport
Bar

Buckle

Wrap Strap under
Seat Belt Mount

Rev. B 1210

LIMITED WARRANTY

We warrant our product to be free from defects in material and workmanship, for the terms specifi ed below, provided there has been normal use and
proper mainte nance. This warranty applies to the original purchaser only. All remedies under this warranty are limited to the repair or replacement of
any item or items found by the factory to be defective within the time period specifi ed.

If you have a warranty claim, fi rst you must call our factory at the number below for instructions. You must retain proof of purchase and submit a
copy with any items returned for warranty work. Upon completion of warranty work, if any, we will return the repaired or replaced item or items to
you freight prepaid. Damage to our products caused by accidents, fi re, vandalism, negligence, misinstallation, misuse, Acts of God, or by defective
parts not manufactured by us, is not covered under this warranty.

THE WARRANTY TIME PERIOD IS AS FOLLOWS: ALL “SOFT GOODS” MANUFACTURED BY OUR COMPANY (USING PRIMARILY VINYLS, PLASTICS,
AND/OR FOAM): ONE YEAR FROM DATE OF PURCHASE.

ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE CREATED HEREBY ARE LIMITED IN DURA­TION TO THE SAME DURATION AND SCOPE AS THE EXPRESS WRITTEN WARRANTY. OUR COMPANY SHALL NOT BE LIABLE FOR ANY INCIDEN­TAL OR CONSEQUENTIAL DAMAGE.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so
the above limitations or exclusions may not apply to you.

This warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state.

For further information or request for warranty work, please contact: Customer Service
877-638-9509

41530 pg 5

Rev. B 1210