SB-PPV2_88.5-95 Suzuki Samurai Proportioning Valve Kit
Contents
1. this calibration procedure 3 Locate an open dry hard surfaced parking lot with no other vehicles around to perform this calibration procedure Calibration procedure requires at least 2 people to perform 1 Driver 1 Observer 4 Drive vehicle slowly and apply brakes to ensure calipers are functioning If vehicle pulls hard in one direction when brakes are applied calipers need inspection Do not perform this calibration procedure if calipers are not functioning properly Consult Suzuki service manual for inspection procedure 5 In an open lot drive vehicle 20 mph and apply brakes in an attempt to lock tires The Observer needs to watch behavior of tires outside the vehicle When braking the Observer will see one of three possible situations A Front and rear tires lock simultaneously and equally B Front tires lock completely with rear tires slightly chirping on the verge of locking C Front tires not locking at all and rear locking completely 6 Proper brake bias will result when situation B in step 5 is reached If situation A occurs rotate proportioning valve dial clockwise 1 4 turn and repeat step 5 If Situation C occurs rotate proportioning valve counterclockwise 1 4 turn and repeat step 5 Although unlikely if adjustment is necessary and no adjustment is left in proportioning valve dial contact Low Range Off Road for assistance Congratulations You have finished the proportioning valve installation We hope t2. Instructions Created by an Automotive Service Excellence 88 5 95 Suzuki Samurai Proportioning Valve Kit SKU SB PPV2 OFF ROAD Installation Instructions CAUTION Safety glasses should be worn at all times when working with vehicles and related tools and Suggested Tools equipment e Tubing Wrench 10mm a e Socket 10 mm e 3 16 Allen Wrench e Ratchet e Combination Wrench 3 8 7 16 amp 1 2 e Brake Fluid DOT 3 e PB Blaster e Twin Post Lift Optional e Floor Jack and 4 Jack Stands Optional Ir ws FOR ADDITIONAL COPIES OF THESE AND OTHER INSTRUCTIONS GO TO www lowrangeoffroad and click on the INSTRUCTIONS tab Ish Al T hd hikes Pes 1195 S 1680 W WWW LOWRANGEOFFROAD CO M Phone 801 805 6644 Orem UT 84058 USA A word about Brake Fluid y 1 Brake fluid will tarnish and in some cases remove paint If brake fluid should accidentally come in contact with painted surfaces flush immediately with clean water 2 Brake fluid can absorb moisture from the air Moisture can lower the boiling point of the brake fluid and cause critical internal brake components to rust For these reasons you should keep the container closed when not pouring from it Further to insure you are using good clean contaminate free brake fluid always use fluid from a sealed container 3 Always use the manufacturer recommend brake fluid Suzuki recommends using DOT 3 Brake Fluid in their Sa
3. cket TAA hed hes i tet fed Ef WWW LOWRANGCEOFFROAD CO MM Phone 801 805 6644 step 16 Install the supplied plug in place of the brake line at Point A using a 3 16 Allen Wrench step 18 Disconnect the rear brake line from the proportioning valve at point C using a 10 mm tubing wrench step 20 Joint the brake line Point C with the brake line point D using the supplied metric union Be sure the fittings are secure and the bake lines are routed in a hazard free area TAGS 1195 S 1680 W Orem UT 84058 USA OFF ROAD step 22 Bleed the brake system according suzuki Service Instructions Note For detailed instructions on bleeding Samurai brakes go to www lowrangeoffroad com Click on Instructions Samurai Instructions Samurai Brake System Bleed Or click HERE if you are viewing these instructions via computer tablet or smart phone Important Note Come back to these instructions after successfully bleeding the system You will need to adjust the proportioning valve See the instructions on the next page ILLI f p Fc 1195 S 1680 W WWW LOWRANIGEOFFROAD COl Phone 801 805 6644 Orem UT 84058 USA Adjusting the Proportioning Valve OFF ROAD step 23 1 Rotate proportioning valve dial counterclock wise completely This will fully decrease rear brake pressure 2 Check tires for proper tire pressure Tires with improper tire pressure will greatly effect
4. fittings are easily rounded Always use a tubing or flare nut wrench to loosen brake lines the first time Step 5 Carefully bend the brake line slightly downward Caution Do not kink the brake line Step 6 Position the proportioning valve assembly as shown and connect the brake line you disconnected earlier to the metric union mee Ei ged d WWU LOWRANIGEOFFROAD COl Phone 801 805 6644 Step 7 Connect the inlet hardline to the master cylinder Leave all fittings hand tight for Now TASS 1195 S 1680 W Orem UT 84058 USA OFF ROAD Toward Toward the J Mast Existing rs a Brake Lines pene Tech Tip 7 Sten 8 Be sure the inlet of the proportioning tep a valve is oriented toward the master Position the proportioning valve as cylinder and the outlet is oriented toward shown here the brake line going toward the wheels Tightening all the fittings Step 9 Step 10 Tighten the fitting at the master cylinder using a 10 mm metric tubing wrench Hold the proportioning valve inlet fitting with a 7 16 wrench and tighten the inlet hard line fitting using a 3 8 open end wrench TELS kaka T F daf lp Fes 1195 S 1680 W WWU LOWRANIGEOFFROAD COl Phone 801 805 6644 Orem UT 84058 USA OFF ROAD step 11 step 12 Repeat Step 10 on the proportioning Hold the metric union with a 1 2 open valve outlet fitting end wrench and tighten the fitting with a 10
5. hese instructions have been helpful If you have suggestions how we could make Our instructions or products better please email US at sales lowrangeoffroad com vy a Vi F a a shed his a M lig 1195 S 1680 W WWW LOWRANGCEOFFROAD CO MM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD As always If you experience any difficulty during the installation of this product please contact Low Range Off Road Technical Support at 801 805 6644 M F 7 30am 5 300m MST Thank you for purchasing from Low Range Off Road These instructions are designed as a general installation guide Installation of many Low Range Off Road products require specialized skills such as metal fabrication welding and mechanical trouble shooting If you have any questions or are unsure about how to proceed please contact our shop at 801 805 6644 or seek help from a competent fabricator Using fabrication tools such as welders torches and grinders can cause serious bodily harm and death Please operate equipment carefully and observe proper safety procedures Rock crawling and off road driving are inherently dangerous activities Some modifications will adversely affect the on road handling characteristics of your vehicle All products sold by Low Range Off Road are sold for off road use only Any other use or application is the responsibility of the purchaser and or user Some modifications and installation of certain aftermarket parts may under certain circums
6. mm open end wrench YS Step 13 Tech Tip 13 Repeat the previous step on the other This is what the proportioning valve fitting connected to the metric coupler assembly should look like when finished TELS kaka T F daf lp Fc 1195 S 1680 W WWW LOWRAIIGEOFFROAD COSM Phone 801 805 6644 Orem UT 84058 USA Lifting and Supporting the Vehicle OFF ROAD Tech Tip step 14 Optional When working on suspension brakes or Lift and support the vehicle on a twin drive train parts it is a good idea to post lift spray all fasteners with penetrating oil a day ahead If not done a day ahead an hour or even minutes before is helpful Note We used a twin post lift but this job could also be done with a floor jack and 4 safety stands It is also possible to do this job with the wheels on the ground if you desire Safety stand See Ul 1195 S 1680 W WWW LOUWURANGCGEOFFROAD CONM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD Use this illustration for Steps 15 through 21 step 15 Disconnect the bypass brake line at Point A using a 10 mm tubing wrench Step 17 Disconnect the bypass brake line from the proportioning valve at point B You could remove this brake from the vehicle line if desired It will not be used step 19 Disconnect the outlet brake line from the proportioning valve at point D Step 21 Remove the proportioning valve by removing the 2 bolts using a 10 mm so
7. murai s and Sidekicks TAA hed hes i tee fed Ee WWW LOWRANGCEOFFROAD CO MM Phone 801 805 6644 OFF ROAD 3 2 4 5 A g 6 vee gt Figure A ay umer bessepton 3 Metric Union 1 not used in this application U M 1195 S 1680 W Orem UT 84058 USA OFF ROAD Brake System Parts Identification amp Component Location 3 ca AL 1 j e ah a Ch F 2 5 ay f Fs l f UG d ED j Ta a a ai oe gt 6 Way Connector Right Front E Left Front FI U a Right Rear O_o i oF Proportioning Valve fo f gt fe by Left Rear i7 g in 310 Master Cylinder dee Ef S hed Ey TAA hed hes WWW LOWRANGEOFFROAD CO M Phone 801 805 6644 TASS 1195 S 1680 W Orem UT 84058 USA OFF ROAD Step 1 eog Install and tighten the outlet fitting using tep a 7 16 open end wrench Install and tighten the inlet fitting in the same way Step 3 Set up the rest of the proportioning valve assembly as shown here Leave all these fittings loose for now and set this assembly aside TELS RAA T sAd l IAA Fc 1195 S 1680 W WWW LOWRANIGEOFFROAD COl Phone 801 805 6644 Orem UT 84058 USA TALL kb hk if i Step 4 Disconnect the front brake line using a 10 mm tubing wrench Caution Brake fluid will leak out You may want to put a cloth or a pan underneath the brake line fitting to catch the drips Note The corners of these
8. tances void your original dealer warranty Modification of your vehicle may create dangerous conditions which could cause roll overs resulting in serious bodily injury or death Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use Revised 05 12 14 Copyright 2014 Low Range Off Road LC All Rights Reserved TELS kaka T F daf lp Fes 1195 S 1680 W WWW LOWRAIIGEOFFROAD COSM Phone 801 805 6644 Orem UT 84058 USA
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