SB-PPV1_86-88.5 Suzuki Samurai Proportioning Valve Kit
Contents
1. Pes 1195 S 1680 W WWW LOWRANGEOFFROAD CO M 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 lt 1195 S 1680 W WWW LOUWURANGCGEOFFROAD CONM Phone 801 805 6644 Orem UT 84058 USA TLS RAI 4 Step 15 Remove the brake line shield by removing the 2 bolts using a 10 mm socket atid eT bs a q e V 1 Jg t sp v Ns o hang LE EI X us ap 4 T RJ Tech Tip 16 Our objective is to swap these two brake lines Note This will allow the front brake line of the master cylinder to control both rear brakes and the rear brake line of the master cylinder to control both front brakes mee Ei ged d WWW LOLURATIG EDFFARDmRD CDITI Phone 801 805 6644 otep 16 Set the shield aside otep 17 Disconnect these two lines from the 6 way connector using a 10mm tubing wrench Note Fluid will run out so place a pan under the fitti2. 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 these instructions have been helpful If you have suggestions how we could make Our instructions or products better please email us at sales lowrangeoffroad com MM a 1 t a shed his a f 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 Th
3. socket ndt fi fed d WWW LOWRANGEOFFROAD COM Phone 801 805 6644 Step 24 Remove the proportioning valve and set it aside Note This part will not be needed for this install IAS 1195 S 1680 W Orem UT 84058 USA OFF ROAD step 25 Step 26 Carefully bend the 2 inlet brake lines Carefully bend the 2 outlet brake lines from a 90 angel to about a 45 angle from a 0 or straight angle to about a as shown 45 angle as shown Step 27 Step 28 Hold the metric coupler using a 1 2 wrench and tighten the fittings using a 10 mm tubing wrench Install the 2 supplied metric couplers as shown Caution Do not cross thread these fittings You may need to bend the brake lines a little more or less to get the fittings to start threading properly TAL Y i Li y F yp E IN A eH 1195 S 1680 W WWW LOLURATIG EDFFARDmRD CDITI Phone 801 805 6644 Orem UT 84058 USA OFF ROAD step 29 Tech Tip 29 Position the brake lines so that they do This is what they should look like when not rub get dented or damaged in any completed way Step 30 Step 31 Double check to see that all the fittings Double check all the brake line connections at the master cylinder Be sure all the fittings are tight and the brake lines are routed in a safe damage fee environment TELS F 7 J pF Fc 1195 S 1680 W WWW LOWRAIIGEOFFROAD COSM Phone 801 805 6644 Orem UT 84058 USA are
4. IGEOFFROAD COl Phone 801 805 6644 otep 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 x Toward Toward the Mast Existing Hin B Brake Line pene Tech Tip 7 Sten 8 Be sure the inlet of the proportioning tep m 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 otep 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 J pF 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 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 F 7 J pF Fc 1195 S 1680 W WWW LOWRAIIGEOFFROAD COSM Phone 801 805 6644 Orem UT 84058 USA OFF ROAD Brake System Parts Identification Propo
5. Instructions Created by an Automotive Service Excellence 86 88 5 Suzuki Samurai Proportioning Valve Kit SKU SB PPV1 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 pg Socket 10 mm 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 e ws FOR ADDITIONAL COPIES OF THESE AND OTHER INSTRUCTIONS GO TO www lowrangeoffroad and click on the INSTRUCTIONS tab Ish Al hd hi Las Pes 1195 S 1680 W WWW LOWRANGEOFFROAD CO M Phone 801 805 6644 Orem UT 84058 USA A word about Brake Fluid IK 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 Samurai s and oi
6. dekicks TAA hed hes i 2J 4N8 JP WWW LOLUR AT TGEDFFA DD COIT Phone 801 805 6644 ama 3 4 od O1 J e 2 E ID P Description Inlet Hard Line PV Inlet Fitting Proportioning Valve Outlet Hard Line Metric Union Metric Plug not used in this application Qty Number a a PV Outlet Fitting a TASS 1195 S 1680 W Orem UT 84058 USA OFF ROAD Step 1 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 sAd l IAA Fc 1195 S 1680 W WWW LOWRANIGEOFFROAD COl Phone 801 805 6644 Orem UT 84058 USA TALL kb hk if i otep 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 fittings are easily rounded Always use a tubing or flare nut wrench to loosen brake lines the first time otep 5 Carefully bend the brake line slightly downward Caution Do not kink the brake line otep 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 LOWRAN
7. ese 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 circumstances 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 J pF Fes 1195 S 1680 W WWW LOWRAIIGEOFFROAD COSM Phone 801 805 6644 Orem UT 84058 USA
8. ngs before you disconnect them Pm ets 1195 S 1680 W OFF ROAD Orem UT 84058 USA OFF ROAD ies TTET oe P otep 18 Carefully bend each brake line and otep 19 reconnect them as shown here Double check all the brake lines at the 6 way connection Be sure all the fittings Caution Be careful If you try to make are tight and the brake lines are routed a bend that is too sharp the tubing will in a safe damage fee location kink restricting flow of the fluid Further once the brake line becomes kinked any attempt to straighten it usually results in breaking the brake line otep 20 Replace the brake line shield Caution Be sure the shield does not rub or contact the brake lines Anything that is in constant contact with the brake lines can rub through over time causing a leak TEL kaka sAd l IAA Fc 1195 S 1680 W WWWLOWRANGEOGFFROGAD CO ST Phone 801 805 6644 Orem UT 84058 USA TELL kb he f i LA ET ay E u otep 21 Loosen all four of the brake lines at the proportioning valve using a 10mm tubing wrench See Figure B for proportioning valve location Caution These fittings can become rusted or corroded You may want to spray them with a good penetrating Bypassing the OEM Proportioning Valve i Re SS i e we lf sw EE a Step 22 Disconnect all four brake lines from the proportioning valve Step 23 Dismount the proportioning valve using a 10mm
9. rtioning Valve F t t d d 1 A Ad 4 4 A Jg A L M FJ g 1 d I Um de pA r dbh Aan Te c ac m E UM m L ik e Ks 4 Me L 4 Mos b Fi 6 Way F Right Rear ha Connector Is la ec we r YU ch i c P uv Us Left Rear y way QEN A 22 o t TAB Right Front uum A C DAR B E 4 T3 Master Cylinder TTA hed hen JspF Jp Pre 1195 S 1680 W WWW LOWRANGCEOFFROAD CO MM Phone 801 805 6644 Orem UT 84058 USA Swapping Two Brake Lines at the 6 Way Connector OFF ROAD This procedure converts the braking system from a diagonal spit braking system to a front rear split system Diagonal split means that one piston in the master cylinder controls the Right Front and the Left Rear Wheels and the other piston controls the Left Front and the Right Rear Wheels See Figure C After completing the procedures outlined below the system will be a front to rear split braking system See Figure D Meaning one piston in the master cylinder will control both front wheels and other piston will control both rear wheels Converting to a front to rear split system will allow for an adjustable proportioning valve to be installed controlling the amount of braking done by the rear wheels Diagonal Split System So Se E xd Front to Rear Split System IN L jJ 4E Pa TTA hed hen JJypyF
10. tight OFF ROAD step 32 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 HEHE 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 Ji f yYpF Jyp Fc 1195 S 1680 W WWW LOWRANIGEOFFROAD COl Phone 801 805 6644 Orem UT 84058 USA Adjusting the Proportioning Valve OFF ROAD step 33 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 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
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