Rhino-Rack Track Mount System

Parts List

Important: Check the contents of kit before commencing fitment and report any discrepancies.

Layout

Diagram showing the layout of the roof rack components.

Tools Required

• Drill Stop
• Power Drill with 5mm Drill Bit
• Vacuum Cleaner
• Felt tip Pen
• Stanley Knife
• Pop Rivet Gun
• Measuring Tape
• Spanner 16mm or 5/8in
• Masking Tape
• Butyl Mastic or Silicon
• Cold Gal & Paint Brush

Installation Steps

1. Insert a rubber strip into each crossbar. Slide two legs into each crossbar. Make sure the channel nut has rotated in the crossbar as shown.

   Diagram illustrating the insertion of rubber strip and legs into the crossbar.

2. Tighten the leg to the crossbar so it can slide for adjustment. Place two end caps on each crossbar.

   Diagram showing the leg tightened to the crossbar and end caps being placed.

3. Slide the eight M6 brass hex nuts into the track as shown. Two brass nuts to each end. Place each assembled crossbar onto the track 50mm from the track end to the closest edge of the track mount leg. Place a M6 spring washer, a M6 x 12.5mm flat washer and a M6 x 35mm security bolt into each leg hole. Fasten the leg to the track.

   Diagram illustrating the placement of hex nuts, crossbars, washers, and bolts.

4. Place assembled crossbars and tracks on top of the vehicles rooftop as shown. Ensure system is adjusted so all measurements are even. The holes in the track are to be marked onto the rooftop. Locate masking tape so when track position is finalised track holes can be marked. Double check your measurements. With a felt tip pen place a mark in the centre of each hole.

   Diagram showing crossbars and tracks positioned on a vehicle roof, with masking tape for marking holes. Text indicates measurements A-A, B-B, C-C should be equal.

5. Place a drill stop on the end of the drill to prevent damaging the rooftop. Drill the marked holes with the 5mm Drill. Make sure to remove swarf with a vacuum cleaner.

   Diagram showing a drill with a stop being used to drill a hole on the vehicle roof.

6. Paint cold gal over each drilled hole. This prevents the bare metal from rusting. Make sure to let the paint dry before proceeding.

   Diagram showing cold gal being applied to a drilled hole.

7. Apply Silicone or Butyl Mastic liberally over and around each drilled hole.

   Diagram showing silicone or butyl mastic being applied around a drilled hole.

8. Remove the crossbars from the track. Cut a strip of adhesive tape off each end of the track to allow for the end cap. Place end caps onto the end track. Remove the paper from the adhesive strips under the track.

   Diagram illustrating the removal of crossbars, cutting tape, and placing end caps.

9. Place the track carefully onto the vehicles rooftop. Place a 5mm Rivet in each hole to allign the track. Use a Pop Rivet Gun to fix the track to the rooftop. Repeat process 5 - 9 for the track on the opposite side of the vehicle.

   Diagram showing rivets being used to fix the track to the roof.

10. Ensure an equal overhang of bar on each side. Tighten the leg to the crossbar to a torque of 20Nm, shown in figure 2. Assemble crossbars to fixed mounted tracks, shown in figure 3. When tightening M6 x 35mm bolts take note of the angle as the leg pulls towards the track. If there is an angle as shown do not continue tightening, it will warp the roof. Remove the crossbar and place two track mount wedges to each leg as shown. Tighten M6 x 35mm Security Bolts to a torque of 5Nm. Store Security Allen Key in a suitable place.

    Diagrams illustrating final tightening of bolts and placement of track mount wedges.

Important Information

Maximum carrying capacity: Your Rhino-Rack is rated to carry 100kg. Please check your vehicles manual for roof load capacity. Always check, and do not exceed, vehicle manufacturers load limitations.

It is essential that all bolt connections are checked after driving a short distance when you first install your Rhino-Rack. Bolt connections should be checked again at regular intervals (probably once a week is enough, depending on road conditions, usage, loads and distances travelled). You should also check the roof bars each time they are refitted.

Crossbars and accessories should be cleaned and all screw threads should be lubricated at regular intervals. Rhino-Rack offers a 3 year warranty to the original purchaser of the Rhino-Rack Track Mount System and Accessories. Rhino-Rack cannot be held responsible for incorrect mounting of the Track Mount System and Accessories or for usage that exceeds vehicle and production tolerances. Make sure to fasten your load securely. Please ensure that all loads are evenly distributed and that the centre of gravity is kept as low as possible.

USE ONLY NON-STRETCH FASTENING ROPES OR STRAPS.

SENSITIVITY TO CROSSWINDS BEHAVIOUR IN CURVES AND BRAKING. The handling characteristics of the car change when you transport a load on the roof. For safety reasons, we recommend you exercise extreme care when transporting wind resistant loads, special consideration must be taken into account when braking.

PLEASE REMOVE CROSSBARS WHEN PUTTING VEHICLE THROUGH AN AUTOMATIC CAR WASH.

LOAD RATINGS Please refer to vehicle specific manual for load rating. When roof bars are to be used in extreme off-road conditions please build a safety factor of 1.5 into the load rating. Although roof bars are tested and approved to AS1235-2000, Australian road conditions can be much more rigorous.

Note for dealers and fitters. It is your responsibility to ensure instructions are given to the end user or client.

RHINO - RACK No: 05

Prepared By: Joseph Ormrod

Authorised By: Gary England

Issue No: RR04

Issue Date: 24/06/03

Rhino-Rack

3 Pike Street, Rydalmere,

NSW 2116, Australia.

(Ph) (02) 9638 4744

(Fax) (02) 9638 4822