SportRack EXPLORER A90095 User manual

EXPLORER
A90095 • A90096 • A90098
LUGGAGE CARRIER INSTRUCTION SHEET
ASSEMBLY COMPONENTS
TOOLS REQUIRED
A
H I J K L M N O P Q R
B C D E F G
S
03347 • 2x 01315 • 1x 03807 • 2x 03808 • 2x 00841 • 2x 03810 • 2x 03396 • 2x
02943 04877 03918 • 4x 00017 00115 04103 01010 00764 00070 03948 03668
10171
4x 8x 4x 12x 8x 4x 4x 8x 4x 4x 1x

EXPLORER
A90095 • A90096 • A90098
Hardshell Top
Hardshell Bottom
Master Parts Bag
–
–
–
––––––
––––––
05305
1
1
1
Snap Latch
Foam Gasket
Camlock with Keys
Lock Locator
Bottom Lock Bracket
Support Assembly
Hinge
U-Bolt
Threaded Knobs
U-Bolt Plate
1/4” Flat Washer
1/4”-20 Plastic Insert Nut
1/4”-20 x 5/8” Screw
10-24 x 5/8” Screw
10-24 Plastic Insert Nut
Large Flat Washer
1/4”-20 Universal Drive Screw •
Small Flat Washer
Vinyl Hole Covers
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
03347
01315
03807
03808
00841
03810
03396
02943
04877
03918
00017
00115
04103
01010
00764
00070
03948
03668
10171
2
1
2
2
2
2
2
4
8
4
4
12
8
4
4
8
4
4
1
Part Description Part Number Qty.
MASTER PARTS BAG
PARTS LIST
Part Description PartNumber Qty.

EXPLORER
A90095 • A90096 • A90098
CARGO BOX ASSEMBLY
Attach foam weather stripping (B) to inside of Carrier top.
DO NOT CUT! Roll out in one piece and trim excess.
Install lock assemblies (C).
NOTE: The locks must be in the “locked” position for assembly to the carrier top and for assembly of the lock locators.
Remove key to prevent movement of lock hook. Lock locator (D) tabs should be pointing toward the inside of the carrier.
Attach hinges (G) to carrier bottom with medium screws (M), medium washers (K) and large plastic insert nuts (L). DO NOT fully tighten at this time.
NOTE: Plastic insert nuts are meant to hold very securely. Screws cannot be tightened by hand but must be driven
through with a screwdriver and pliers or adjustable wrench.
2
3BOTTOM ASSEMBLY
TOP ASSEMBLY
CUTAWAY OF HARDSHELL TOP
TABS
INSTALLED IN LOCKED POSITION
C
D
1

EXPLORER
A90095 • A90096 • A90098
ASSEMBLING TOP TO BOTTOM
While someone holds the top, align the slot in the hinges (G) on the Carrier bottom
with the Carrier top and attach medium screws (M), medium flat washers (K)
and large plastic insert nuts (L). DO NOT FULLY TIGHTEN AT THIS TIME.
While someone holds the top in an open position, attach the support assemblies (F)
with the 2 large screws (Q), 4 large flat washers (P) and 2 large plastic insert nuts (L).
Tighten screws until snug, (overtightening could cause binding).
Note: White plastic protectors in the center of the support assemblies
must be facing inwards.
Attach front and back snap latches (A) to bottom with 4 small screws (N), small
flat washers (R) and small plastic insert nuts (O).
5
4
6

EXPLORER
A90095 • A90096 • A90098
10
Attach lock brackets (E) to Carrier bottom on passenger side with
medium screws (M) and large plastic insert nuts (L).
Use lower slots in lock brackets. DO NOT FULLY TIGHTEN.
Check for correct alignment of lock assembly by closing and locking the carrier. If the lock
properly engages the bottom lock bracket, open the Carrier and tighten the hinge (G) hardware and
the lock bracket (E) hardware. If the lock does not align with the lock bracket and does not lock
properly, adjust the hinge and lock bracket hardware until they lock. Tighten hardware.
To close Carrier, make sure the locks are in the open (horizontal) position with the key removed and pull Carrier top downward from both ends.
To lock Carrier, insert key, pull down on flange and turn key to the locked position (vertical). Place snap latches into top flange depressions and push front
of snap latches down until they engage. FOR SAFETY, THE CARRIER LOCKS (C) MUST PROPERLY ENGAGE THE BOTTOM LOCK BRACKET (E) AND THE FRONT
AND REAR SNAP LATCHES MUST BE ENGAGED WHENEVER THE VEHICLE IS IN MOTION.
NOTE: Some deformation of the plastic top may occur in shipping. It may be necessary to reshape the hardshell bottom by pressing in on the top flange
against the bottom flange all around the Carrier and locking the Carrier. Within 48 hours the top and bottom will reshape and fit together more readily.
The Carrier may be used during this reshaping period.
CAUTION
Check that latches are engaging brackets. Top should not lift up when pulled.
All locking devices must be engaged (and keys removed) whenever the vehicle is in motion.
OPEN LOCKED
7
8
9

EXPLORER
A90095 • A90096 • A90098
U-BOLT MOUNTING
H
E
I
J
When carrier is assembled, place on the crossrails, place U-Bolts (H) under crossrails and assemble U-bolts through Carrier bottom mounting
holes and U-bolt plates (J). Secure with threaded knobs (I). Recheck to see that your crossrails are securely locked into position.
For safety the hooks in the carrier locks must properly engage the lock brackets (E) whenever the vehicle is in motion.
Periodically check all mounting hardware for tightness.
To help prevent water from entering your Carrier vinyl covers (8) are included for any unused holes.
Cleaning: Clean with mild soap and water.
Storage: To prevent warping when storing, close and latch. Do not store items on top of carrier.
13
14
12
11
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