Thule Evo Flush Rail Fitting Kit 186068 Instruction Manual

1. Introduction

This manual provides instructions for the proper installation, operation, and maintenance of the Thule Evo Flush Rail Fitting Kit 186068. This kit is specifically designed to enable the secure attachment of Thule Flush Rail feet to vehicles equipped with integrated roof profiles, such as the Mazda 6 Sedan (2013-).

Please read this manual thoroughly before installation and retain it for future reference. Adherence to these instructions ensures safe and effective use of your Thule roof rack system.

2. Safety Information

• Always follow the specific instructions provided with your Thule roof rack system and vehicle manufacturer's recommendations.
• Ensure all components are correctly installed and tightened according to the torque specifications in the detailed assembly instructions.
• Do not exceed the maximum load capacity of 75 kg (165 lbs) for the roof rack system, or the vehicle manufacturer's recommended roof load, whichever is lower.
• Regularly check the tightness of all bolts and fasteners, especially before long journeys and after driving on rough roads.
• Distribute the load evenly on the roof rack. Secure all cargo properly to prevent shifting during transit.
• Be aware of the increased vehicle height and width when driving with a roof rack and cargo, especially when entering garages, car washes, or low-clearance areas.
• Adjust driving speed to suit road conditions, cargo, and weather. Avoid sudden braking, acceleration, or sharp turns.

3. Package Contents

The Thule Evo Flush Rail Fitting Kit 186068 includes the following components:

• Specific vehicle mounting brackets (4 pieces)
• Rubber pads/protectors (4 pieces)
• Fasteners and bolts
• Detailed assembly instructions (vehicle-specific)

Image 1: All components included in the Thule Evo Flush Rail Fitting Kit 186068. This includes four main bracket assemblies, four smaller metal clips, and four bolts.

Image 2: A close-up view of one of the metal fitting brackets, showing its design for secure attachment to integrated roof rails.

Image 3: The packaging box for the Thule fitting kit, displaying the Thule logo and "KIT" label.

4. Setup & Installation

The Thule Evo Flush Rail Fitting Kit 186068 is designed for a vehicle-specific fit. Always refer to the detailed assembly instructions included in your package for precise, step-by-step guidance tailored to your Mazda 6 Sedan (2013-).

4.1 Pre-Installation Checks

• Verify that all components listed in Section 3 are present and undamaged.
• Clean the vehicle's roof and integrated rail areas where the kit will be installed to ensure a secure fit and prevent paint damage.
• Identify the specific mounting points on your vehicle's integrated flush rails as indicated in the detailed instructions.

4.2 Installation Steps (General Overview)

1. Attach Brackets: Position the vehicle-specific brackets onto the integrated flush rails according to the detailed instructions. Ensure they align with the designated mounting points.
2. Secure with Fasteners: Use the provided fasteners and bolts to secure the brackets to the vehicle. Tighten them to the specified torque settings using an appropriate tool. Over-tightening can damage the vehicle or components; under-tightening can lead to an insecure fit.
3. Install Rubber Pads: Place the protective rubber pads between the brackets and the vehicle's surface to prevent scratches and ensure a snug fit.
4. Mount Thule Feet: Once the fitting kit is securely installed, attach your Thule Flush Rail feet (sold separately) to the installed brackets, following the instructions provided with the feet.
5. Final Check: After installation, gently pull and push on the entire roof rack system to ensure it is firmly attached and does not move. Re-check all fasteners for tightness.

5. Operating Instructions

5.1 Load Capacity

The maximum load capacity for the Thule Evo Flush Rail Fitting Kit, when combined with appropriate Thule feet and bars, is 75 kg (165 lbs). This limit includes the weight of the roof rack system itself. Always adhere to the lower of either the Thule specified load capacity or your vehicle manufacturer's recommended roof load limit.

5.2 Securing Cargo

• Distribute cargo weight evenly across the roof bars.
• Use appropriate Thule accessories (e.g., straps, cargo boxes, bike carriers) to secure items firmly.
• Ensure no part of the cargo obstructs the driver's view or interferes with vehicle operation.

5.3 Driving with a Roof Rack

• Drive at reduced speeds, especially in crosswinds, on rough roads, or when cornering.
• Be mindful of increased vehicle height and width.
• Check the roof rack and cargo for security and tightness frequently during long trips.

6. Maintenance

6.1 Regular Inspection

• Periodically inspect all components of the fitting kit and roof rack system for signs of wear, damage, or corrosion.
• Check the tightness of all bolts and fasteners at least once a month, and always before and after carrying heavy loads or long journeys.

6.2 Cleaning

• Clean the fitting kit and roof bars with mild soap and water. Avoid harsh chemicals or abrasive cleaners that could damage the finish or materials.
• Rinse thoroughly and dry completely to prevent water spots and corrosion.

6.3 Storage

If the roof rack system is not in use for an extended period, consider removing it from the vehicle to reduce wind noise, improve fuel efficiency, and minimize wear on components. Store the kit in a dry, cool place away from direct sunlight.

7. Troubleshooting

7.1 Loose Fit

If the fitting kit or roof rack feels loose after installation or during use:

• Check Torque: Re-tighten all bolts and fasteners to the specified torque settings as per the detailed assembly instructions.
• Verify Placement: Ensure the brackets are correctly positioned on the vehicle's integrated flush rails according to the vehicle-specific instructions.
• Inspect Components: Check for any damaged or missing parts that might compromise the fit.

7.2 Excessive Wind Noise

Some wind noise is normal with a roof rack. However, if it's excessive:

• Check Bar Position: Ensure the roof bars are correctly positioned and spaced according to the instructions.
• Inspect End Caps: Verify that all end caps and covers on the roof bars are securely in place.
• Remove Accessories: If noise persists, remove any attached accessories (e.g., bike carriers, cargo boxes) to determine if they are the source.

7.3 Scratches or Marks on Vehicle

If you notice marks on your vehicle's paintwork:

• Ensure Cleanliness: Always clean the vehicle's roof and the underside of the fitting kit components before installation. Dirt or grit trapped between surfaces can cause scratches.
• Verify Pads: Ensure all protective rubber pads are correctly installed and are not displaced.
• Check for Movement: A loose fitting kit can rub against the paint. Re-check all fasteners for tightness.

8. Specifications

9. Warranty Information

Thule products are tested and are subject to strict quality controls. Thule guarantees all products against defects in material and workmanship. For specific warranty terms, conditions, and duration, please refer to the official Thule website or the warranty documentation included with your complete Thule roof rack system.

Please note that this fitting kit is part of a larger roof rack system. The overall warranty may depend on the complete system.

10. Customer Support

For further assistance, technical support, or to inquire about replacement parts, please contact Thule customer service through their official website. You may need to provide your product model number (186068) and proof of purchase.

Thule Official Website: www.thule.com

Always refer to the most current information available on the official Thule website for up-to-date support contacts and product information.