User Manual

1. Introduction

This manual provides essential information for the safe and effective installation, operation, and maintenance of your apline FLY Model Car Roof Rack Cross Bars. This product is designed to carry loads on your vehicle and is required for the assembly of accessories such as bicycle carriers, ski carriers, and roof boxes.

This roof rack system is specifically designed for Daihatsu Terios 2 (J200) models manufactured between 2006 and 2017, which feature existing roof rails with a gap between the vehicle roof and the rail. It is not suitable for vehicles without roof rails or those where the roof rail is flush with the roof.

Image: Three black aluminium roof rack cross bars, showcasing the product's design and finish.

2. Safety Information

• Always ensure all components are securely fastened before driving.
• Do not exceed the maximum load capacity specified for the roof rack or your vehicle's roof.
• Distribute the load evenly across the bars.
• Check fasteners periodically, especially after the first few miles of driving and after long trips.
• Be aware of increased vehicle height and potential wind resistance when carrying loads.
• Avoid sudden braking or sharp turns when carrying heavy loads.

3. Compatibility Check

This roof rack system is designed for vehicles with existing roof rails that have a visible gap between the rail and the vehicle's roof. Please verify your vehicle's roof rail type before installation.

Image: Visual guide illustrating compatible roof rail types (with a gap) and incompatible types (flush or sunroof obstruction).

4. Package Contents

Verify that all components listed below are present in your package:

• 3 x Aluminium Rods (fully compatible with the vehicle in the title)
• 6 x Aluminium Bar Connection Kits
• 6 x Head Brackets
• 6 x Elastomer Head Bracket Protectors
• 6 x Bottom Brackets (GF30 PA6 or Electro Static Painted S 235 Steel for some vehicles)
• 6 x Elastomer Bottom Bracket Protectors
• 6 x Bolts (+ or ⬡ head)
• 6 x Nuts
• 1 x Allen Key (if the bolt has ⬡ head)

Image: An overview of all included components, including the three aluminium bars, brackets, bolts, nuts, and the Allen key.

5. Setup and Installation

Installation of the roof rack is designed to be simple and can be completed by one person without professional support. Ensure your vehicle is parked on a level surface and the engine is off before beginning.

1. Prepare the Bars: Identify the three aluminium bars. Note that they may have different lengths (a > b > c) or be of equal length (a=b=c) depending on your vehicle model.
2. Assemble Brackets: Attach the head brackets and bottom brackets to the ends of each aluminium bar. Ensure the elastomer protectors are correctly positioned to prevent scratching your vehicle's roof rails.
3. Position on Roof Rails: Carefully place the assembled bars onto your vehicle's roof rails. The bars should be evenly spaced for optimal load distribution. Refer to the diagram for suggested positioning (e.g., front, middle, rear).
4. Secure the Bars: Using the provided bolts and nuts, secure each bracket to the roof rail. Use the Allen key (if applicable) to tighten the bolts. Ensure all connections are firm and secure. Do not overtighten.
5. Final Check: After installation, gently shake each bar to confirm it is securely attached and does not wobble. Double-check all bolts for tightness.

Image: Step-by-step visual guide for the initial stages of roof rack installation, including bar preparation and securing to roof rails.

Image: Continuation of the installation guide, demonstrating the final tightening of the bars and illustrating the maximum load capacities and speed limits.

Note: Unless an incorrect purchase is made, there is no need to cut the aluminium bars.

6. Operating and Usage

Once installed, your roof rack is ready for use. Always adhere to the specified load limits to ensure safety and product longevity.

Load Capacity:

• Moving Vehicle: The aluminium bars can carry up to 75 kg (165 lbs) when the vehicle is in motion.
• Parked Vehicle:
  • For a product consisting of 3 bars (as this model), a maximum load of 225 kg (496 lbs) is recommended.
  • For 2 bars: 150 kg (330 lbs)
  • For 4 bars: 300 kg (661 lbs)

Image: Technical diagram illustrating the maximum load capacities for both moving and parked vehicles, along with a recommended maximum speed of 120 km/h when loaded.

General Usage Tips:

• Always secure your cargo properly using appropriate straps or tie-downs.
• Ensure cargo does not obstruct your view or interfere with vehicle operation.
• Be mindful of overhead clearances when driving with cargo on the roof.
• For optimal performance and safety, maintain a speed of 120 km/h (75 mph) or less when carrying loads.

7. Maintenance

Regular maintenance will prolong the life of your roof rack and ensure continued safe operation.

• Cleaning: Clean the aluminium bars and plastic components with mild soap and water. Avoid abrasive cleaners or solvents that could damage the anodized finish or plastic.
• Fastener Check: Periodically check all bolts and nuts for tightness, especially after long journeys or if you notice any unusual noise. Retighten as necessary.
• Component Inspection: Inspect the elastomer protectors and brackets for any signs of wear, cracking, or damage. Replace any damaged components immediately.
• Storage: If removing the roof rack for extended periods, store it in a clean, dry place away from direct sunlight.

8. Troubleshooting

Here are some common issues and their potential solutions:

• Issue: Roof rack feels loose or wobbles after installation.
  Solution: Re-check all bolts and nuts. Ensure they are tightened securely. Verify that the brackets are correctly seated on the vehicle's roof rails.
• Issue: Unusual noise (whistling, rattling) while driving.
  Solution: This can be caused by wind resistance or loose components. Check all fasteners. Ensure cargo is securely tied down and not vibrating. Adjust bar spacing if possible to reduce wind noise.
• Issue: Scratches on vehicle roof rails after installation.
  Solution: Ensure elastomer protectors are correctly installed and not displaced. These are designed to prevent direct contact between metal components and your vehicle's surface.
• Issue: Cannot install the bars onto the roof rails.
  Solution: Double-check your vehicle's compatibility. This product requires roof rails with a gap. If your vehicle has flush rails or no rails, this product is not suitable.

9. Specifications

Image: Detailed technical drawing showing the dimensions of the roof rack components and illustrating the maximum load capacities.

10. Warranty and Support

For warranty information and technical support, please refer to the manufacturer's official channels. While specific warranty details are not provided in this manual, apline products are generally covered by standard manufacturer warranties against defects in materials and workmanship.

For further assistance, you may visit the manufacturer's support page or contact their customer service:

apline Official Support Page

Image: The image below highlights key features of the Apline roof rack system, such as its aerodynamic design, secure fit, vehicle-specific design, and weatherproof properties.