Rhino-Rack RSPTS03 User manual

TOWARDS CENTRE
OF VEHICLE ROOF.
Take note of track orientation when placing in the roof
channel. Both tracks are the same.
2
Gently lever the rubber roof trim starting with a screwdriver
(wrap tape around end of screwdriver to prevent paint
scratching) then using fingertips pull carefully upwards.
Small plastic clips are attached to the roof underneath
each end of the strip.
1
Layout
Tools Required:
Pneumatic or concertina
rivet gun.
Marking pen.
Power or Cordless drill.
5mm drill bit.
Drill bit depth stop.
Vacuum cleaner.
Cold galvanizing solution &
brush.
Selleys Butyl Mastic,
Caulking Gun.
5mm Security Allen key,
provided in kit.
Measuring tape.
Flat Head screwdriver.
Phillips Head screwdriver.
Rubber mallet.
Care Instruction:
Clean vehicle roof prior to fitting Rhino Heavy Duty Racks.
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Parts List
Item Component Name Single Cab Extra Cab Dual Cab Part No.
1 Track Mount End Cap FL & RR 2 2 2 M215
2 Track Mount End Cap FR & RL 2 2 2 M214
3 Hilux Track 1 Pair 1 Pair 1 Pair
4 Rhino Sportz Rubber Buffer Strip 1 2 2 R011
5 Rhino Sportz Crossbar 1 2 2 A155
6 M6 x 35mm Security Screw 2 4 4 B092
7 M6 Spring Washer 2 4 4 W004
8 M6 x 12.5mm Flat Washer 2 4 4 W003
9 RSP Sportz Leg 2 4 4 M094
10 RSP Top Pad 2 4 4 M173
11 RSP Bottom Pad 2 4 4 M172
12 M6 x 16 Dowel Nut 2 4 4 N027
13 M6 Dowel Nut Housing 2 4 4 A341
14 10G x 1/2” Pan Head Phillips Screw 2 4 4 B045
15 Rivet 7 9 11 H005
16 5mm Security Allen Key 1 1 1 Seckey-S
17 Fitting Instruction 1 1 1 RS-82
Maximum carrying capacity: 100kg
Toyota Hilux - Rhino Sports Two Bar Track Mount System
Place these instructions in the vehicle’s glove box after installation is complete.
Important: Please read these instructions carefully prior to installation.
Please refer to your fitting instruction to ensure that the roof racks are installed in the
correct locations.
Check the contents of kit before commencing fitment and report any discrepancies

FRONT
10
Using either a pneumatic or concertina type rivet gun,
rivet the track into place. Make sure all rivets are seated
firmly onto the base of the track.
NOTE:
Start at the FRONT
and work back so the
track can be pulled
down to follow the
roof curve.
TOWARDS CENTRE OF VEHICLE ROOF.
9
Peel the backing tape off the track. Accurately place the
track over the drilled holes in the roof channel using the
rivets to position. Make sure track orientation is correct.
STEP 1. STEP 2.
8
Apply a liberal amount of cold galvanizing solution to the
inside and surrounds of all holes. Allow cold galvanizing
solution to dry, three to four minutes, then apply a liberal
amount of Selleys Butyl Mastic in and around each hole.
7
Use a vacuum to remove swarf from the roof channel.
NOTE:
USE CARE WHEN BREAKING
THROUGH. A DRILL STOP IS
RECOMMENDED.
6
Marked out holes can now be drilled through using a
5mm drill bit and drill stop. Set the drill stop to ensure you
don’t drill through the roof lining. Use of a drill stop will
alleviate the need to remove the hood lining.
5
Accurately centre punch all holes before drilling.
210mm
REAR
4
Hold track down tight in roof channel. Mark all holes
using a marking pen. Remove the track.
210mm
FRONT (Dual Cab
measurement
shown)
3
Place the track in the channel and measure from the edge
of the windscreen rubber to the front of the track. The
use of masking tape will help maintain this measurement
while marking out holes for drilling.
Windscreen Rubber to Track
Measurements
Single Cab Extra Cab Dual Cab
245mm 315mm 210mm

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Prior to final fitment of the second Cross bar/Leg assembly, do a trial placement and measure the distance inbetween.
Cut the rubber roof trim to this measurement. Slide the rubber roof trim into the Track as shown.
Measure
(trim shown in place)
Slide rubber trim
into the Track
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Place the bottom pad over the Dowel Nut Housing then Top Pad. Sit the Leg/Cross bar assembly on the Top Pad.
Place the M6 Security Screw and washers through the hole in the Leg as shown and screw into the Dowel Nut.
Tightening torque is 3-4Nm. Tighten after positioning both sides equally.
M173 <PA6-GF25>
Tangs face towards
outside of vehicle
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Insert the rubber buffer strip into the top of the cross bar.
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From the underside of the cross bar insert the Phillips
head screw.
12
Insert the Sportz leg fully into the cross bars, a rubber
mallet may be required to knock the leg in place.
Dowel Housing sits
between this section.
Slide Dowel Nut
into Housing.
11
Push the Dowel Nut into the Dowel Nut Housing with the
thread facing up through the hole. Slide the unit into the
top ‘U’ section of the track.

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Showing the the fitted rubber roof trim in place for a neat appearance.
With the Leg/Crossbar units tight and fixed in place the rubber roof trim can be cut and slid in place to cover the
exposed areas of the Track at each end. The End Cap is designed to sit over the rubber roof trim after it is cut.
Therefore there is a generous tolerance on the measurement of the rubber roof trim.
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Step 1.
Measure and cut the
trim then slide into
the track.
Step 2.
Clip End Cap into the Track
to cover end of trim.
Measure
Rubber trim sits
under End Cap
Inside edge buts up
against end of track.
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Showing the orientation of the End
Caps after installation. Caps are LEFT
and RIGHT handed..
FRONT VIEW
Measure and cut the rubber roof trim and put back in the vehicle roof
channel at the front and rear ends of the Track. The front piece needs
to be measured so the end of it sits under the windscreen rubber. The
measurement and cutting of the rubber roof trim isn’t critical since the End
Cap will cover it. Recommend using a fine tooth hacksaw because of metal
inside the rubber roof trim.
Rear of vehicle
Cut trim 5-10mm from
end of Track.
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Important Information
Maximum carrying capacity: 100kg
Recommendations:
It is essential that all bolt connections be checked after driving a short distance when you first
install your cross bars.
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
cross bars 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.
Sensitivity to cross winds, behaviour in curves and braking.
The handling characteristics of the vehicle, changes when you transport a load on the roof.
For safety reasons, we recommend you exercise extreme care when transporting wind-resisting
loads; special consideration must be taken into account when braking.
Please remove cross bars when putting vehicle through an automatic car wash.
Load Ratings:
Maximum permissible load is 100kg per pair of cross bars (include the weight of the cross bars,
5kg). When cross bars are to be used in off-road conditions, please build a safety factor of 1.5
into this load limit. 67kg for off road conditions. Although the roof racks are tested and approved
to AS1235-2000, Australian road conditions can be much more rigorous. However, increasing
the number of cross bars does not increase the vehicles maximum permissible roof loading.