Whispbar K991W User manual

K991W
Fitting Kit
EN Fitting Instructions for Basic Carrier CAUTION: Professional
installation recommended
x 2 x 1 x 1 x 4
x 4 x 1 x 4 x 4
x 8 x 1 x 4
Revision No: 1A 1

Fitting Kit K991W
MAX kgs (lbs)
W/P WHD
Toyota
Hilux Double Cab, 4dr Ute 16-+ ZA 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Double Cab, 4dr Ute 16-+ EU 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Double Cab, 4dr Ute Oct 15-+ AU 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Double Cab, 4dr Ute Oct 15-+ NZ 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Extra Cab, 4dr Ute 16-+ EU 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Extra Cab, 4dr Ute 16-+ ZA 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Extra Cab, 4dr Ute Oct 15-+ AU 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Extra Cab, 4dr Ute Oct 15-+ NZ 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Single Cab, 2dr Ute 16-+ EU 35 kgs (77 lbs) 50 kgs (110 lbs)
Hilux Single Cab, 2dr Ute 16-+ ZA 35 kgs (77 lbs) 50 kgs (110 lbs)
Hilux Single Cab, 2dr Ute Oct 15-+ AU 35 kgs (77 lbs) 50 kgs (110 lbs)
Hilux Single Cab, 2dr Ute Oct 15-+ NZ 35 kgs (77 lbs) 50 kgs (110 lbs)
2

Fitting Kit K991W
X
A B C 1 2 3
Hilux Double Cab, 4dr Ute 16-+ (ZA) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
Hilux Double Cab, 4dr Ute 16-+ (EU) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
Hilux Double Cab, 4dr Ute Oct 15-+ (AU) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
Hilux Double Cab, 4dr Ute Oct 15-+ (NZ) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
Hilux Extra Cab, 4dr Ute 16-+ (EU) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
Hilux Extra Cab, 4dr Ute 16-+ (ZA) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
Hilux Extra Cab, 4dr Ute Oct 15-+ (AU) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
Hilux Extra Cab, 4dr Ute Oct 15-+ (NZ) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
Hilux Single Cab, 2dr Ute 16-+ (EU) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
Hilux Single Cab, 2dr Ute 16-+ (ZA) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
Hilux Single Cab, 2dr Ute Oct 15-+ (AU) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
Hilux Single Cab, 2dr Ute Oct 15-+ (NZ) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
3

Fitting Kit EN
K991W
Items you will require:
●Tape measure
Pen
Flat-head screwdriver
Craft knife
Side cutters or tin snips
Hammer
8mm (3/8") punch
Cordless drill
Depth stop
Vacuum cleaner
Rust inhibitor
Small paint brush
Neutral cure silicon sealant
Rivet gun
Attention:
●Attaches with riveted mounts under rubber
ditch mould. Professional installation
advised.
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Fitting Kit EN
K991W
First Time Installation
●Remove parts from inside the package and
check. Contact your dealer if any parts are
missing or damaged.
●This kit fits type A, B, C and D.
●These instructions show type A crossbar
fitted. They also apply to type B, C and D.
●Use keys to remove covers.
5

Fitting Kit EN
K991W
●Use hex screwdriver to reverse adjusting
screw 10 turns.
●Press adjusting screw and pull crossbar
legs out. Refer to the crossbar instructions
for crossbar adjustment method.
●Ensure each end of the crossbar is
adjusted equally.
●Adjust crossbar in or out to suit vehicle.
●Please check the front of this manual for
information relating specifically to your
vehicle.
6

Fitting Kit EN
K991W
●Remove plastic clamp block by gripping bar
leg with fingers and push firmly with
thumbs until clamp block drops out behind
leg.
●Select plastic internal block (from fitting kit)
and insert into foot.
●Repeat for all legs.
●CAUTION:
●RECOMMENDED POSITION DUE TO
AIRBAGS IN ROOF:
●Please check the front of this manual for
information relating specifically to your
vehicle.
●Apply masking tape to vehicle roof in all
four positions.
●Mark reference point on masking tape with
a pen.
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Fitting Kit EN
K991W
Permanent Mount Fitment
●Carefully cut tape to seperate ditch mould
from roof.
●Repeat for all four positions.
●Line up the centre hole in the mounting
block with the marked reference points.
●Wrap tape around rubber ditch mould to
mark end position of mount.
●Ditch mould held at each end by:
●Front:
●Plastic retaining clip
●Rear:
●Double sided tape
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Fitting Kit EN
K991W
●Apply protective tape as shown.
●Carefully remove ditch mould at the front
position with flat-head screwdriver.
●Unhook rubber ditch mould from plastic
retaining clip (A) and double sided tape (B).
Lift ditch mould up and out of the channel.
●Completely remove from the vehicle.
●The rubber ditch mould is to be re-installed
on the vehicle later.
●Turn rubber ditch mould over.
●Place on a workbench.
From the bottom, cut 3/4 of the way
through the rubber ditch mould as shown.
Blade should contact steel strip.
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Fitting Kit EN
K991W
●Carefully cut rubber ditch mould between
faces along steel strip.
A = Top face
B = Bottom face
●A = Top
B = Bottom
C = Steel strip
D = Removed excess
●Check fit.
10

Fitting Kit EN
K991W
●Cut steel strip in centre using side cutters.
●Lift and cut steel strip at each end.
●Remove cut peices of steel strip.
●Repeat for all four positions.
●Turn rubber ditch mould over.
●Punch 8mm (3/8") hole through top of
rubber ditch mould, centered on mark as
shown.
Remove excess from hole.
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Fitting Kit EN
K991W
●Removed excess
●Position as shown.
●Line up the centre hole in the mounting
block with the marked reference points.
●Lightly mark position of outside holes of the
mounting block in the roof channel.
12

Fitting Kit EN
K991W
●Note:
●Assemble as shown.
●CAUTION:
●RECOMMENDED POSITION DUE TO
AIRBAGS IN ROOF:
●Please check the front of this manual for
information relating specifically to your
vehicle.
●CAUTION: Maximum depth 8mm.
Use 8mm drillstop over supplied 4.9mm
drill bit.
Drill two outside holes at marked positions.
●Vacuum and clean swarf from channel.
13

Fitting Kit EN
K991W
●Treat holes to prevent corrosion.
●Apply neutral cure silicon sealant in and
around drilled holes.
●Install rivets through permanent mount
blocks.
●Rivet into place.
14

Fitting Kit EN
K991W
●Apply as shown.
●Rear:
●Double sided tape
●Re-install rubber ditch mould in roof
channel.
Remove all masking tape.
●Ensure the hole in rubber ditch mould lines
up with mount.
15

Fitting Kit EN
K991W
●Select grubscrews and screw into the
vehicle's fixed points.
●Do not over tighten.
●Repeat for all four positions.
●Refer to the underside of the pad for the
part number.
●It is important to put the pads in the correct
position on the vehicle.
●Letters refer to the pad part numbers and
position.
●Pad Part Number:
A = 244
B = 293
C = 294
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Fitting Kit EN
K991W
●Fit rubber pads (supplied with fitting kit) to
foot. Pad may vary in shape to that shown.
●Make sure the pad fits into the holes
underneath the foot.
●Place crossbar foot over grubscrews.
●Tighten the plastic knob.
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Fitting Kit EN
K991W
●Ensure the plastic knob is in the position
shown when fully tightened.
●Tighten adjusting screw to 2 Nm (1.5 ft lb)
hand tight.
●Check crossbar is securely attached to the
vehicle.
●Use keys to fit and lock covers
18

Fitting Kit EN
K991W
CAUTION: Recheck all fasteners immediately after
a load is applied to the crossbars.
Regularly check screws are tight.
19

Fitting Kit EN
K991W
Maintenance
●Clean the car roof and surfaces of the
product that will be in contact with the car
roof.
●Follow the fitting instructions for fitting the
product to your vehicle. Make sure all steps
are carried out in order.
●Set crossbars a minimum distance of
700mm (27 1/2") apart where no other
distance is specified in the fitting
instructions. This is especially important
when carrying long loads.
●Check unit is securely attached whenever
you refit it to the vehicle. If the unit feels
loose, refer to the fitting instructions and
readjust.
●Some glass/panoramic roofs and radio
antennae may not be able to be used when
the product is fitted.
●Do not modify this product.
●Refer to the maximum permitted load
capacity specified in the fitting instructions.
Do not exceed the vehicle manufacturers
roof load rating if it is lower than the
maximum load capacity specified in the
fitting instructions.
●Loads should not overhang the sides of the
product and be evenly distributed with the
lowest possible centre of gravity.
●Long loads should be secured with non-
elastic straps to the front and rear of the
vehicle.
●Objects with pointed ends (e.g. ski poles)
should be carried with the pointed ends to
the rear of the vehicle.
●Remove all loose or removable objects
from the load prior to loading.
●Make sure all loads are securely fastened
with non-elastic straps. Check regularly
during longer journeys.
●A loaded roof rack system can alter the
performance of your vehicle. Be especially
aware of the effects of side winds,
changing of direction, and braking
performance. Avoid rapid acceleration and
deceleration. Drive carefully.
●Note that the total height of the vehicle
increases when upright loads are carried.
●Products should be locked during transport
if they have locks fitted.
20