Rhino-Rack Suzuki Jimny Overland Kit
ROLS1
Document No: 520-RFI-00115 | Issue No: 01 | Issue Date: 30/01/2022
Important Information
Important:
- Check the Rhino-Rack website to ensure you have the latest issue of these instructions.
- Please refer to your fitting instruction to ensure that the product is installed correctly.
- Check the contents of the kit before commencing fitment and report any discrepancies.
- Place these instructions in the vehicle's glove box after installation is complete.
- These instructions must be followed for warranty to be upheld.
Fit Time: 45 mins
Installer Skill Level: DIY ⚙️
Load Management and Safety Guidelines
Load Distribution:
- ✔️ Distribute loads evenly and laterally/longitudinally as low as possible over the span.
- ❌ Avoid point loads concentrated at the front or rear.
Transporting Loads:
- Exercise extreme care when transporting wind-resistant loads. Special consideration must be taken when cornering and braking.
- Off-road conditions can be much more rigorous. Extreme care must be taken on any driven path that does not contain a surface protection layer (tar/bitumen). ⚠️
Securing Loads:
- ❌ Long flexible loads must attach securely to rigid support and be tied down to the bonnet.
- ✔️ Long flexible loads must attach securely to rigid support and be tied down to the bonnet.
- ❌ Surfboard Overhang > 600mm must be tied to the bonnet.
- ✔️ Surfboard Overhang > 600mm must be tied to the bonnet.
- ❌ Loads must be tied down to the Platform, not around legs.
- ✔️ Use only non-stretch fastening ropes or straps to attach cargo to roof racks.
Vehicle Compatibility & Warnings:
- ❌ Do NOT obstruct windscreen camera sensors.
- ✔️ Warranty for roof rack system will be void if the front of the kayak is not secured to the bonnet. ⚠️
- ❌ Racks must be removed when the vehicle is put through an automatic car wash.
- ⚠️ Manufacturers' roof load limit does not support the use of rooftop tents.
- Ensure sunroof will not collide with roof rack system. ⚠️
Maintenance and Checks
In-service maintenance checks:
- All bolt connections should be checked after driving a short distance when you first install your roof racks.
- All bolted connections should be checked again at regular intervals (weekly is recommended, depending on road conditions, usage, loads and distances travelled).
- All bolted connections should be checked each time they are re-fitted.
- Off-road conditions are more rigorous. Check all bolted connections and your load more regularly.
- Ensure that your vehicle manufacturer's GVM, and gross axle weights are not exceeded (refer to vehicle owner's manual).
Torque Settings:
Unless stated otherwise in these instructions, all fasteners should be set to the following torque settings:
| Fastener Size | Torque Setting (Nm) | Torque Setting (lbs/ft) |
|---|---|---|
| M6 | 4-5 Nm | 3-4 lbs/ft |
| M8 | 8-10 Nm | 6-7.5 lbs/ft |
| M10 | 16-18 Nm | 12-13 lbs/ft |
Load Limit Information
Dynamic Load Limit (On and Off-Road):
*Use the vehicle manufacturer's maximum roof allowance if it is lower than the figure listed.
| Component | Limit |
|---|---|
| CARGO | UP TO 10 kg (22 lbs) |
| SYSTEM WEIGHT | + 20 kg (44 lbs) |
| LOAD LIMIT | OR UP TO 30 kg (66 lbs) |
| *VEHICLE MANUFACTURER'S ROOF LOAD LIMIT |
Platform Height: 70mm / 2 3/4" above the highest point on the vehicle's roof.
Parts List
P1: Platform Assembly
- A Side Extrusion x2
- B Front/Rear Extrusion x2
- C Plank x4
- D Underbar x2
- E LHS Backbone x1
- F RHS Backbone x1
- G RHS Corner Base (100-005-00001) x2
- H RHS Corner Cover (100-003-00001) x2
- I LHS Corner Base (100-005-00002) x2
- J LHS Corner Cover (100-003-00002) x2
- K M6 x 25mm Hex Head Flanged Bolt x48
- L M6 x 12mm Hex Head Flanged Bolt x4
P2: Backbone Installation
- M M6 x 16mm Hex Head Flanged Bolt x4
- N M6 x 19mm Flat Washer x4
- O 150mm Generic Pinch Weld x4
- L M6 x 12mm Hex Head Flanged Bolt x10 (Note: Part L used again)
P3: Vehicle Installation
- K M6 x 25mm Hex Head Flanged Bolt x8 (Note: Part K used again)
- P Gutter Backbone Strap x4
- Q Gutter Backbone Clamp x4
- R 10mm Socket Hex Driver x1
Tools Required
- S Torque Tool x1
- T Torx Key (T30) x1
- U Instructions x1
- T1 - Socket Wrench
- T2 - Tape Measure
Installation Steps
P1: Platform Assembly
Step 1
Align parts G (RHS Corner Base) and I (LHS Corner Base) with parts B (Front/Rear Extrusion). Ensure correct orientation marked "FRONT". Attach G and I to B using bolts K (M6 x 25mm Hex Head Flanged Bolt).
Visual: Shows parts G, I, B, and K being assembled. Labels indicate "FRONT".
Step 2
Assemble the main frame by connecting parts A (Side Extrusion) to the previously assembled sections. Ensure the frame is square.
Visual: Shows two parts A being connected to the frame.
Step 3
Insert and partially tighten bolts K (M6 x 25mm Hex Head Flanged Bolt) to connect the frame components. Use the Torque Tool S and Socket Wrench R. Indicate "TIGHTEN" with arrows.
Visual: Shows bolts K being inserted and tightened into the frame.
Step 4
Attach the planks C to the frame using bolts K. Ensure planks are evenly spaced.
Visual: Shows planks C being attached to the frame with bolts K.
Step 5
Attach parts H (RHS Corner Cover) and J (LHS Corner Cover) to the frame using bolts L (M6 x 12mm Hex Head Flanged Bolt). Ensure correct orientation.
Visual: Shows corner covers H and J being attached with bolts L.
Step 6
Attach the underbars D to the frame using bolts K. Use the Torque Tool S and Socket Wrench R. Torque setting indicated: 6Nm / 4.4LB/FT.
Visual: Shows underbars D being attached with bolts K, with torque tool S and socket R.
Step 7
Final tightening of all bolts K using Torque Tool S and Socket Wrench R. Torque setting indicated: 6Nm / 4.4LB/FT.
Visual: Shows torque tool S and socket R tightening bolts K.
Step 7a
Shows the fully assembled platform with all planks and frame components.
Step 7b
Indicates final tightening points with arrows and part code L.
P2: Backbone Installation
Step 8
Attach the LHS Backbone E and RHS Backbone F to the platform assembly. Use bolts M (M6 x 16mm Hex Head Flanged Bolt) and washers N (M6 x 19mm Flat Washer). Use Torque Tool S and Socket Wrench R. Torque setting indicated: 6Nm / 4.4LB/FT.
Visual: Shows backbones E and F being attached with bolts M and washers N.
Step 9
Insert the 150mm Generic Pinch Welds O into the designated slots on the platform assembly.
Visual: Shows pinch welds O being inserted.
Step 10
Shows the assembled platform being tilted or maneuvered, indicating it's ready for placement.
Visual: A dynamic illustration of the rack assembly.
Step 11
Attach the assembled platform to the vehicle's roof rails/gutter mounts. Use bolts L (M6 x 12mm Hex Head Flanged Bolt). Use Torque Tool S and Socket Wrench R. Torque setting indicated: 6Nm / 4.4LB/FT.
Visual: Shows bolts L being tightened onto the vehicle mounts.
P3: Vehicle Installation
Step 12
Demonstrates lifting the assembled rack onto the Suzuki Jimny's roof. Shows side cross-section and rear view of placement. Ensure correct alignment.
Visual: Two people lifting the rack onto the vehicle. Close-up of side cross-section showing attachment points.
Step 13
Indicates a required spacing of 500mm between the front and rear mounting points on the vehicle's roof.
Visual: Shows the rack positioned on the vehicle roof with a 500mm measurement.
Step 14
Shows opening the vehicle door to access the mounting points inside the vehicle.
Visual: Vehicle door open, indicating access to the interior mounting area.
Step 15
Secure the rack to the vehicle's gutter mounts using Gutter Backbone Straps P and Gutter Backbone Clamps Q. Use bolts K. Use Torque Tool S and Socket Wrench R. Torque setting indicated: 6Nm / 4.4LB/FT. Shows LH SIDE CROSS SECTION.
Visual: Close-up of the LH side attachment point with parts P, Q, K, R, S.
Step 16
Secure the rack to the vehicle's gutter mounts on the RHS using Gutter Backbone Straps P and Gutter Backbone Clamps Q. Use bolts K. Use Torque Tool S and Socket Wrench R. Torque setting indicated: 6Nm / 4.4LB/FT. Shows RH SIDE CROSS SECTION.
Visual: Close-up of the RH side attachment point with parts P, Q, K, R, S.
Step 17
Shows the vehicle with the fully installed roof rack system.
Visual: A final illustration of the Suzuki Jimny with the Overland Kit installed.
Maintenance
Use Torx Key T to retighten bolts at steps 4 and 8.
Use Torque Tool S and Socket Wrench R to retighten bolts at steps 15 and 16.
Visual: Shows the "TIGHTEN" action with the Torx Key T and Torque Tool S with Socket R.
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