Rhino 2500 Series - Two Bar Heavy Duty System

Important Information

Please refer to your fitting instruction to ensure that the roof racks are installed in the correct locations. 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.

Maximum carrying capacity: 75kg (165lbs) evenly distributed over crossbars. Please refer to your vehicle manufacturer's handbook and DK Specification sheet for maximum roof loading. Always use the lower of the two figures.

Recommendations:

• It is essential that all bolt connections be checked after driving a short distance when you first install your crossbars.
• 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 crossbars each time they are refitted.
• 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.

Load Ratings

When these roof racks are to be used on a vehicle that is driven off sealed roads, the manufacturer's maximum roof load rating (to be found in the vehicle's User Manual) should be halved. For example, if the vehicle's maximum roof load rating is 70kg (subtract 5kg - weight of crossbar and legs), these racks, when fitted to this vehicle, should have no more than 35kg loaded on them.

Caution:

The handling characteristics of the vehicle 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 cornering and braking. Please remove crossbars when putting the vehicle through an automatic car wash.

Note for Dealers and Fitters:

It is your responsibility to ensure instructions are given to the end user or client.

Safety and Load Warnings

The following diagrams illustrate important safety and load carrying information:

✔️ Diagram showing a vehicle with correctly installed roof racks. ✔️ Diagram showing a wheel/tire and a person checking bolts, indicating proper maintenance.

⚠️ Diagram showing a vehicle with roof racks positioned too far forward, indicating incorrect placement. ❌ Diagram showing a vehicle with roof racks in an automatic car wash, indicating removal is necessary.

⚠️ Speedometer indicating caution with speed (km/h). 2 x Crossbars = 5kg (This indicates the approximate weight of the crossbars themselves). A diagram shows a question mark over a load on a vehicle roof, implying the need to check load limits.

Load rating comparison: A vehicle on an "Urban road" has a "70kg load rating", while the same vehicle "Off road" has a "35 kg load rating (Off road - 70kg / 2)".

WARNING! Important Load Carrying Instructions:

With utility vehicles, the cabin and the canopy move independently. Roof racks and the vehicle can be damaged if the item transported is rigidly fixed at points on both the cabin and canopy. Instead, rigidly fix to either the cabin roof racks or the canopy roof racks. A diagram shows incorrect fixing (rigidly to both cabin and canopy) with a ❌, and correct fixing (to cabin roof racks or canopy roof racks) with a ✔️.

Parts List and Tools Required

Carrying Capacity: Refer to DK specification sheet for maximum carrying capacity of your particular vehicle.

Tools Required: Security Allen key (provided in kit), Tape measure, Rubber mallet.

Pad & clamp kit available separately.

NOTE: Refer to the DK kit specification sheet for correct placement (Front & Rear, Left & Right) of the foot plate, rubber pad and metal strap. Also refer for sizes to cut the bar measurement strips.

Hardware Attachment Steps:

Diagrams showing hardware attachment:

a. Attach the heavy duty cross bar adaptor onto the top of the leg. Push to snap in place. b. Locate the M6 x 25mm security screw, spring washer, and flat washer through the top of the leg and fasten to the M6 channel nut. Do not tighten at this stage. c. Make sure the M8 pivot is correctly located as shown below. An annotation indicates: "Angled face of pivot nut faces out."

Installation Steps

1. Attach pad to foot plate.

   Clip the rubber pad onto the foot plate. The pad's centre tube and end tabs must fully locate into the foot plate. Note: Certain rubber pad sets have a DK supplement sheet to show correct orientation.

   Diagrams show the rubber pad being clipped onto the foot plate. Annotations indicate "Centre tube" and "End tabs". Another diagram shows the "Centre tube pushes through" and "End tabs clip in".

2. Attach foot plate to leg.

   Clip the foot plate onto the base of the leg with the arrow facing In or Out according to your vehicle listed in the DK specification sheet. The diagram at the left shows the arrow facing Out.

   A diagram shows the foot plate being clipped to the leg. An example from a "DK spec sheet" shows "Foot Plate", "Arrow Dir.", and "OUT".

3. Crossbar rubber:

   Push the cross bar rubber buffer strip into the top of the bar.

   Diagram shows the rubber strip being inserted into the top channel of the crossbar.

4. Attach cross bar:

   a. Locate the leg with the channel nut into the cross bar. b. Turn to locate the channel nut to sit across the bar.

   Diagrams show the leg being inserted into the crossbar and the channel nut being positioned. Annotation: "Channel nut must sit across the bar."

5. Measurement between legs:

   Accurately measure between the legs to set the correct distance. Refer to DK specification sheet for vehicle-specific distance. Also set equal cross bar overhang. Tighten M6 security screw to 4-5 Nm (35-44 lbf.in).

   Diagram illustrates measuring the distance 'x' between legs and setting equal overhang. Annotations include "DK spec sheet", "HD Cross Bar", "distance (x)", "example size only.", "Equal over hang", and "Measure to edge of heavy duty cross bar adaptor."

6. Leg location decals:

   Stick the leg position labels inside the leg. The labels are used to easily identify front and rear cross bars if they are removed from the vehicle. Refer to the layout below.

   Diagram shows a leg with a "Decal" inside. Smaller diagrams show the leg location labels: "RR" (REAR RIGHT), "RL" (REAR LEFT), "FR" (FRONT RIGHT), "FL" (FRONT LEFT).

7. Position roof racks:

   Place racks onto the vehicle roof. Refer to DK specification sheet for correct positioning of your roof racks. A. Measure forward from a centre line of where the front and rear doors meet/close. B. Measure back to set the distance between cross bars. A and B measurements are to be in line with the arrow in the centre of the foot plate.

   Diagram shows roof racks positioned on a vehicle roof, with measurements A and B indicated from center lines. "Arrow on foot plate" is shown.

8. Positioning decals:

   Stick the white arrow decals in line with foot plate arrows onto the bodywork inside the door jamb. This marks reference points for future use when racks are removed and then replaced.

   Diagram shows arrow decals being applied inside the door jamb, aligned with foot plate arrows. An upward arrow is depicted.

9. Attach clamps:

   a. Hook the lower part of the metal clamp in at the top of the door jamb underneath any rubber seals that may be present. Fasten the M8 bolt to the pivot nut in the leg. b. Bolts must be tensioned evenly on each side of the vehicle to avoid pulling the rack to one side. Do not tighten one side at a time. Tighten M8 bolt to 12-14 Nm (106-123 lbf.in). Refer to DK instruction for correct clamp and pad combination for front and rear of vehicle. c. Knock end caps into the end of cross bars. A rubber mallet may be used.

   Diagrams illustrate the clamp attachment process, including hooking the clamp, even bolt tensioning, and fitting end caps.

10. Attach front cover:

    Insert the two lugs on the left side of the front cover into the leg. Use the key provided to turn the lock barrel to the open position (O). Engage the locking tab into the leg. Turn to close (C).

    Diagram shows the front cover being attached and the lock barrel being operated with a key to open and close the cover.

Vehicle Specific Fitting Data (DK077)

Front Cross Bar Specifications

Rear Cross Bar Specifications

Positioning of Cross Bars on the Roof

Measurement A: CENTRE of door jamb to CENTRE of Front cross bar.

Measurement B: CENTRE of Front cross bar to CENTRE of Rear cross bar.