Rubicon Expedition Products Corral User manual

Section 1: Corral Bike Rack™ Hitch Mechanism Installation
Part 1 - Hitch Mechanism Installation………………………….…..Page 2
Section 2: Corral Bike Rack™Assembly and Installation
Part 1 - Center Column Assembly…………………………………….Page 3
Part 2 - Upper Cross Bar Assembly….…………..……...….….…..Page 5
Part 3 - Lower Cross Bar Assembly……………………….……….…Page 7
Part 4 - Wheel Basket Assembly………………………………………Page 8
Part 5 - Wheel Basket Installation…………………………………...Page 9
Part 6 - Lasso & Velcro Strap Assembly………….………….…..Page 11
Section 3: Corral Bike Rack™ Use, Tips, & Tricks
Part 1 - Raising & Lowering your Corral Bike Rack™…..…..Page 12
Part 2 - Placing bikes on your Corral Bike Rack™…………….Page 13
Part 3 - Removing bikes from your Corral Bike Rack™…...Page 14
Part 4 - Adjusting Safety Latch Tension…………………..……..Page 15
Section 4: Troubleshooting
Part 1 - Troubleshooting Solutions Table……………..…….….Page 16

P a g e | 1 Corral Bike Rack™ Manual
Disclaimer and Warning
Congratulations on purchasing your new RubiconEP product. The
information in this document affects your safety and your legal rights
and responsibilities. Read this entire document carefully to ensure
proper configuration before use. Failure to read and follow instructions
and warnings in this document may result in serious injury to yourself or
others, damage to your Corral Bike RackTM, or damage to other objects
in the vicinity. This document and all other collateral documents are
subject to change at the sole discretion of RubiconEP. For up-to-date
product information, visit https://rubiconep.com/corral. Do not use
Corral Bike RackTM with other or incompatible components or otherwise
alter this product in any way outside this or other documentation
provided by RubiconEP.
By using this product, you hereby signify that you have read this
disclaimer and warning carefully and that you understand and agree to
abide by the terms and conditions herein. You agree that you are solely
responsible for your own conduct while using this product, and for any
consequences thereof. You agree to use this product only for purposes
that are detailed in this document and in accordance with all applicable
laws, rules, and regulations, and all terms, precautions, practices, and
guidelines RubiconEP has made and may make available.

Corral Bike Rack™ Manual P a g e | 2
Corral Bike Rack™Assembly Instructions:
Included in your new RubiconEP Corral Bike Rack™is everything
required for assembly and installation. The quantity of certain parts will
depend on the size of the bike rack ordered. For example, if you
ordered a 4-bike Corral Bike Rack™, you should have received 4 Wheel
Baskets with Basket Clamps, and so on. If you ordered a 5-bike rack,
your quantities would be 5. Please verify that all parts are present:
A) 1 Center Column with linkages
B) 1 Hitch Mechanism with Silent Hitch Pin
C) 1 Upper Cross Bar
D) 2 Center Brackets for a 2-bike rack and 3 for a 4 or 5-bike rack
E) 1 Lower Cross Bar
F) 2, 4 or 5 Wheel Baskets with Basket Clamps
G) 2, 4 or 5 Riser Brackets
H) 2, 4 or 5 Upper Lassos
I) 2, 4 or 5 Lower Lassos
J) 2, 4, or 5 Velcro Straps
K) 1 Parts Kit*: 1/8” Hex Allen wrench , ¼” Hex Allen wrench, 5/32”
Hex Allen wrench, and one bottle of Medium Strength (blue)
Loctite. *not pictured
Note: Before you begin, grab a tape measure, 2 crescent wrenches,
and a Philips head screwdriver.
___________________________________________________________

P a g e | 3 Corral Bike Rack™ Manual
Section 1 –Hitch Mechanism Installation
Part One: Hitch Mechanism Installation
1) Let’s start by installing your new Hitch
Mechanism (B) on your vehicle. We find that
this helps make the assembly of your Corral
Bike Rack so much easier.
2) Find that Hitch Mechanism and the included Let’s Go Aero Silent
Hitch Pin. This pin allows the Hitch Mechanism to be installed so
that it will not move around in the receiver. And that my friends, is
important!
3)
4) Now, the LGA pin comes pre-installed in the most
extended position. However, if you would like to
adjust it so that your rack sits closer to the vehicle,
simply remove the Hitch Mechanism, move the
spring nut to a different hole, and reinstall. Done
and done!
5) The image on the far right shows a Hitch
Mechanism properly installed.
___________________________________________________________
STEP 1: Insert the Spring Nut into the hitch
accessory shank tube. Align the Spring Nut’s coil
with the hitch receiver pin hole.
STEP 2: With the Spring Nut compressed within the
accessory shank, slide the shank into the vehicle’s
hitch receiver and align the hitch pin holes.
STEP 3: Insert the Silent Hitch Pin with the Split
Washer into the hitch pin hole and thread the pin
through the threaded block side of the Spring Nut as
shown.
STEP 4: Slide the sleeve into the hitch pin hole so
that it slides over the hitch pin. Using a 7/8”
wrench, fully tighten the Pin so it is snug and tight;
secure with clip. You are now ready for Safe and
Silent Towing.

Corral Bike Rack™ Manual P a g e | 4
Section 2 –Corral Bike Rack™Assembly & Installation
Part One: Center Column Assembly
1) Now for the fun part!
2) Locate Center Column (A). The Hitch Mechanism
should already be installed on your rig.
3) First, we need to check that the bearings did not
become mis-aligned during shipping. To do this,
insert the ¾” axle through the opening indicated
in the picture to the right. If it slides all the way
through, you are set. If it does not, then they
are not aligned, and you can simply use the axle
as a lever to re-align them.
6) Slide the ¾” axle from the outside of the Hitch Mechanism in,
through the welded internal sleeve in the bottom of the Center
Column. This part can be a little tricky as you need both holes in the
bottom of the Center Column to align with each of the holes on the
sides of the Hitch Mechanism. Don’t be shy! Ask a friend for help!
4) Next, hold the Center Column with the
linkages at the bottom, closest to the
ground, and the handle facing you.
5) Insert the Center Column into the
receiver tube of the Hitch Mechanism,
aligning the bottom hole with the
bearing openings on each side.

P a g e | 5 Corral Bike Rack™ Manual
7) Once the ¾” axle rod is fully inserted, use a
Philips head screwdriver to tighten the screw
on the bottom of the Center Column, securing
it in place.
8) Finally, using the 1/8” Allen wrench, tighten the two
small, black set-pins on the left and right sides of
the ¾” axle. Note: This means you should have
tightened 4 in total. #Math.
11) Once it passes through that first hole, add a bushing to it.
12) Next, slide it through the rod end, and add your second bushing.
13) Finally, slide the bolt through the hole on the opposite side of the
Hitch Mechanism.
14) Add the nut to the end of the bolt and use a ¾” socket or box end
wrench and crescent wrench to tighten. - Included?
15) The picture to the right shows the Center
Column and Hitch Mechanism correctly installed
on the vehicle.
9) Next, we will insert the Yellow-Zinc
plated bolt through the openings on
each side of the Hitch Mechanism, and
the rod end in the center.
10) Slide the bolt from the right to the left,
through the first hole in the Hitch
Mechanism.

Corral Bike Rack™ Manual P a g e | 6
Part Two: Upper Cross Bar Assembly
1) Locate the Upper Cross Bar (C) and your Center
Brackets (D).
2) Pull up on the safety trigger of the Hitch
Mechanism and lower the Center Column into
the lean-to-load position.
3) Pull down firmly on the top of the Center
Column until you feel it lock into the lowered
position.
4) Hold the Upper Cross Bar out in front of you with the longest
section on top, and the smaller section below.
7) Spacing will vary, depending on whether you have a 2, 4, or 5-bike
rack. Additionally, placement of the Upper and Lower Cross Bars
will intentionally stagger them. This is essential to the proper
functionality of your Corral Bike Rack™.
8) Using the chart below, determine the correct placement of your
Upper Cross Bar. Note: “centerline” denotes the very center of the
Center Column horizontally, from left to right.
Placement
5-Bike Rack
4-Bike Rack
2-Bike Rack
Upper
Cross Bar
27.5” (70 cm) from
left end of cross bar
to centerline
27.5” (70 cm) from
left end of cross bar
to centerline
11” (28 cm) from left
end of cross bar to
centerline
5) Place the Upper Cross Bar
behind the Center Column and
position it so that is about 0.5”
(1.3 cm) from the top.
6) Now, let’s set your spacing.

P a g e | 7 Corral Bike Rack™ Manual
9) Slide that Upper Cross Bar until it is correctly positioned.
10) Then, ask a friend to help hold it in place
while you work on the bottom Center
Bracket. #worksmarternotharder
11) Using the 5/32” Allen wrench, remove the
hardware from the largest plate of each of
the Center Brackets. This is the top plate.
14) Ensure the 4 bolts on the bottom (small) plate of the
Center Bracket are secure.
15) Then, reattach the larger, top plate and LOOSELY
ASSEMBLE THE HARDWARE, adding a small amount of
medium strength Loctite (blue) to each of the 8 bolts
as you go. Just a tad. Don’t get too excited. And
don’t stress. We already did the other side.
DO NOT overtighten one side of the
bracket as it can DAMAGE it!!!
A GAP BETWEEN THE TOP PLATE &
PARTS BELOW WILL REMAIN.
We are serious. These are the facts.
12) Hold one Center Bracket so that the
longest section is horizontal, and
the open section is facing away
from you, towards the vehicle.
13) Place it over the Center Column and
bottom section of the Upper Cross
Bar.
16) Then, using a crisscross pattern,
lightly tighten each of the bolts on
the top of the Center Bracket using
the 5/32” Allen wrench.