Windshield Fold Down Kit

Betsy Mikel

Everyone else in the whole world got fold down windshields on their Suzuki's. Not in the United States. Why? I guess maybe just because our government does not think we are smart enough to have fun and be safe about it. So these parts are all made by the Suzuki factory and are MEANT to be on your truck!

We got our kit of parts from our friend Mr. Wakefield at SUMMIT/ROCKY ROAD. Dad sent him an e-mail for the kit on Monday and the UPS man brought it on Thursday. I think that is pretty good.

First get all of the tools and parts:

MATERIALS:
(2) Windshield latches for the side of the dashboard
(2) Windshield clamps for the side of the dash, there will two, left and right
(2) Hinges
(2) Rubber Bumper things -- they go on top of the windshield
(1) Hood strap -- this has studs and nuts on it
(1) Windshield strap -- this has holes for screws
(1) Nylon belt for hooking up the folded down windshield to the hood

TOOLS:
Impact Screw Driver
Phillips Screwdrivers (a couple of different sizes)
Ballpeen hammer (my Dad says you should never use a claw hammer to work on cars)
Electric Drill
Drill bits
Center Punch
10mm socket
Ratchet

Not included in the kit, but you might want to get:

A handful of extra screws (in case you drop some or want to replace some of the ones you'll be taking out.)
Plastic tubing and a connector that extends the windshield washer connection. You can buy these at your local pet store in the fish section.

Ok, before you start, remember ... Put your hair up if its long enough to wear in a pony tail. You don't want to get it caught in the engine. Wear safety glasses, if you don't already wear eye glasses. That to undo screws turn counter-clockwise, to put a screw in turn clockwise.

And remember to use common sense on and off road with the windshield down (like a tree twig could snap in your face if you're acting crazy and there is no windshield up).

All right now, you can start!

	The first thing to do is put your materials aside and take the roof bars off. There are four -- two over the doors and two more for the roof from the windshield to the Targa Bar. You can put the bars and screws back on when you have to put the windshield up really quick (like if it rains). You might want to find a good place in your truck for the bars and screws. Sometimes these screws get rusty and hard to get out. Use the impact screw driver. My Dad says you can get a pretty good one at Sears. And if you break it, they have to give you a new one free. You hit it with the Ballpeen hammer while you twist it counter-clockwise. Then you can use the Phillips screwdrivers to take them out.
	There is a bracket on the sides of the dashboard that you have to take off. There are four screws to take out. These will be easier.
	Here is where you put the latches and clamps. It's kind of hard to explain how they go. The picture will help your figure it out. It will also help to look at the bracket you just took off. Take my word, you'll be able to do it. When you have the four bars off, but the windshield up, the latches and clamps keep the windshield up and sturdy (like, from not falling down).
	Now work on the top of the windshield. There are four screws, two on each side. They are painted over. Take these out. This is where the hood rubber bumper things go. One on each side. There is already a rubber bumper in the center of the windshield. Ours was glued on with black stuff. Use a flat screw driver to pry it off. Scrape this black stuff off and underneath, you will find two screw holes. This is where you put the windshield tie-down strap. Get screws to go through the strap into the windshield.
	Next you add the hinges. On the front of the windshield, on each side by the hood, are plastic pieces that cover up the brackets which we have to remove. Take the flat screw driver and pry them off. They are stuck on with sticky tape stuff. Behind these are the brackets, with three screws in each of them. Remove the screws and brackets and just replace them with the hinges.
	On all true Suzuki's there are already two holes for the hood strap started on the bottom of the hood. If you see the braces, there are two holes there! Use the center punch and punch a dot in the center of each of these holes. It will make just like a little nick. Now take a drill bit a little smaller than the bolts on the hood strap. When you start the bit, the dot you punched will keep the drill from wiggling around out of control. Drill through the hood from the bottom. Now you turn the hood over and drill bigger holes to fit the bolts on the hood strap. If you use two drill bits like this you won't mess up your hood metal too much. To put the hood strap on, align it with the two holes you just drilled in the hood. Drop in two studs and hold the strap down with your fingers while you add a nut to each stud on the bottom side of the hood. (You might need extra hands here). Use the ratchet and socket to tighten them. Dad added rubber washers between the strap and the hood to keep water out, which is silly because sometimes we drive IN water.
	Okay! Now your fold down windshield is done. Be careful when you fold it down, it might be heavy for you. On the passenger's side, the motor for the wipers will pop out of a little compartment. Keep the plastic top that goes here so you can put it back when the windshield is up. Use the nylon strap to buckle the hood and windshield straps together. There is one thing more that is optional. When folding the windshield down, we noticed that the little tube that carries the windshield washer fluid was too short to work when the windshield was down. We also noticed that the tubing was the same thing that we use in our fishtank to transport air. Using some extra tubing and a connector, we found that we could wash the windshield anytime, even folded down! Just remember to push the extra tubing inside when you fold the windshield up.
	Well, that's it. It was a sunny day and a little cold when we took our first ride with the doors off and the windshield down. But I know this will be a lot of fun in the summer.