R O A D M A S T E R, I N C.

Transcription

1 R O A D M A S T E R, I N C. BASEPLATE KIT ITEM QTY NAME MATERIAL /2" x 2 1/2" BOLT /2" x 1 3/4" CARRIAGE BOLT /2" FLAT WASHER /2" LOCK WASHER /2" HEX NUT mm x 1.25 x 50mm BOLT mm FLAT WASHER mm LOCK WASHER /8" DRAW PIN W/ CLIP QUICK LINK SAFETY CABLE 8" " O.D. x WALL x 3/4" PIPE SPACER...A /4" X 1 1/2" x 2 1/2" BACKING PLATE...A /4" x 1 3/4" x 7 3/16" BACKING PLATE...A MAIN RECEIVER...C DRIVER SIDE ARM...C PASSENGER SIDE ARM...C FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE

2 This is one of our XL series brackets, which allows the visible front portion of the bracket be easily removed from the front of the vehicle (Fig.A and Fig.B). The bracket kit consists of a main receiver brace, two removable front bracket arms and a hardware pack. The main receiver brace mounts the p and botm of the frame rails, and the removable front bracket arms install in the main receiver braces. Bee starting the installation, lay out the kit components in order, as they will be used. This will give you a visual idea of how the components work, and will also confirm that everything is present and accounted. Fig.A Fig.B IMPORTANT: All brackets must be assembled with all the bolts left loose final adjustment and positioning (bee tightening) unless otherwise instructed. All bolts must be rqued proper strength. If more than one bolt is used per fastening point, the diagram may only show one. Use flat washers over all slotted holes Use lock washers on all fasteners ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carn. follow these instructions can result in property damage, WARNING personal injury or even death. Installation of most mounting brackets requires moderate mechanical aptitude and skills. We strongly recommend professional installation by an experienced installer. The installer must read the instructions and use all bolts and parts supplied. When the securely do instructions so could fasten result require the in bracket loss the of reuse could the wed of result facry vehicle. in loss bolts, of Use the thread wed Loctite lock vehicle. and/or Red lock on all washers bolts used must also mounting be used. this bracket. securely fasten the bracket could result in loss of the wed vehicle. Do not use this document cusm fabrication, as it may not show Do all parts not use or structural this document components. cusm Cusm fabrication, fabrication as or it may an attempt not show all copy parts this or bracket structural design components. could result Cusm in loss fabrication of the wed or an vehicle. attempt copy this The owner bracket must design inspect could all mounts result loss of and brackets the wed vehicle. Every 3,000 miles, the owner must inspect the fasteners bee each proper use Every rque, cracks 3,000 according miles, other the signs bolt owner of rque fatigue. must requirements inspect Also, inspect the chart fasteners the on fasteners the last proper page rque, of proper these according rque, instructions. according the The bolt owner rque the bolt must requirements rque also requirements inspect chart all on mounts the chart last on page and the of brackets last these page. instructions. cracks do The or so other owner could signs result must of in also fatigue loss inspect of the every wed all 3,000 mounts vehicle. miles. and brackets The owner do must so cracks could or check result other the vehicle in loss signs of of manufacturer's the fatigue wed vehicle. every 3,000 miles. instructions the proper do so could procedure(s) result in loss of prepare the wed vehicle. The owner must check the vehicle manufacturer's the vehicle instructions wing. Some The the vehicles proper owner must must procedure(s) be equipped check the with vehicle prepare a transmission manufacturer's the vehicle lube pump, instructions wing. an axle Some disconnect, proper must driveline procedure(s) be equipped disconnect with or prepare a free-wheeling transmission the vehicle hubs lube pump, bee wing. an they axle can Some dis- be vehicles connect, wed. must driveline be equipped properly disconnect equip with or free-wheeling the transmission vehicle will hubs lube cause bee pump, severe they an axle damage can dis- be connect, wed. the transmission. driveline properly disconnect equip or free-wheeling the vehicle will hubs cause bee severe they damage can be wed. properly equip the vehicle will cause severe damage vehicles the If running the transmission. changes were made by the vehicle manufacturer after this bracket the transmission. If running was changes designed, were some made bolts by or the other vehicle fasteners manufacturer in the hardware after this If bracket pack running may was no changes designed, longer be were some the made correct bolts by size. or the other vehicle It is fasteners the manufacturer installer s the responsi- hardware after this bracket pack bility may was verify no designed, longer that the be bracket some the correct bolts is securely size. or other It is fastened fasteners the installer s the the vehicle responsibility pack fitted may with verify no the longer correct that the be hardware bracket the correct is securely account size. It is fastened these installer s changes. the vehicle responsi- and bility fitted securely with verify fasten the correct that the the bracket hardware bracket could is account securely result in fastened loss these of the changes. wed the vehicle vehicle. and fitted securely with fasten the correct the bracket hardware could account result in loss these of the changes. wed vehicle. hardware and securely fasten the bracket could result in loss of the wed vehicle. If the wed vehicle has been in an accident, it must be properly re- If paired the wed bee vehicle attaching has the been bracket. in an Do accident, not install it must the be bracket properly if any repaired structural bee frame attaching damage the is bracket. found. Do not install repair the bracket damage if could any structural structural result in the frame frame loss damage damage of the wed is is found. found. vehicle. repair repair the the damage damage could could result result Some in in morhome the the loss loss of of chassis the the wed wed have vehicle. vehicle. such tight turning radius that you can Some Some damage morhome morhome your morhome, chassis chassis wed have have such such vehicle, a tight tight w turning turning bar or bracket radius radius that that while you you turning can can damage damage sharply. your your Bee morhome, morhome, getting on wed wed the vehicle, vehicle, road, test w w your bar bar or or turning bracket bracket radius while while turning turning an sharply. sharply. empty parking Bee Bee getting getting lot. Turning on on the the o road, road, sharply test test could your your result turning turning radius radius non-warranty in in an an empty empty damage parking parking wing lot. lot. system, Turning Turning morhome o o sharply sharply and/or could could wed result result vehicle. in in non-warranty non-warranty damage Do not back wing up with system, the morhome wed vehicle and/or attached wed vehicle. or non-warranty Do Do damage not not back back will occur up up with with your the the wed wed wing vehicle vehicle system, attached attached morhome or or and/or non-warranty non-warranty wed damage damage vehicle. will will occur occur your your wing wing system, system, morhome morhome and/or and/or wed wed vehicle. The safety cables must connect the wing vehicle the wed The The vehicle safety safety frame cables cables frame, must must with connect connect the cables the the wing wing crossed, vehicle vehicle with enough the the wed wed slack vehicle vehicle sharp frame frame turns. frame, frame, Refer with with the the the cables cables instructions crossed, crossed, with with proper enough enough routing. slack slack sharp sharp leave turns. turns. enough Refer Refer slack the the in cable cable the safety instructions instructions cables, failure proper proper routing. routing. connect the safety leave leave cables enough enough frame slack slack frame, in in the the will safety safety result cables, cables, in the or or loss failure failure of the connect connect wed the the vehicle. safety safety cables cables frame frame frame, frame, will will result result in in the the loss loss of of the the wed wed vehicle. This bracket is designed use with ROADMASTER w bars and This This ROADMASTER bracket bracket is is designed designed adaprs only. use use Using with with this ROADMASTER ROADMASTER bracket with other w w bars bars brands, ROADMASTER ROADMASTER without an approved adaprs adaprs ROADMASTER only. only. Using Using this this adapr, bracket bracket may with with result other other brands, brands, in non- without without warranty an an damage approved approved or injury. ROADMASTER ROADMASTER adapr, adapr, may may result result in in nonwarranty Upon final damage installation, or injury. the installer must inspect the bracket en- Upon non- Upon sure adequate final final installation, installation, clearance, the the particularly installer installer must must around inspect inspect hoses, the the air bracket bracket conditioner ensure ensure lines, adequate adequate radiars, clearance, clearance, etc., or non-warranty particularly particularly around around damage hoses, hoses, the air air wed conditioner conditioner vehicle lines, lines, will result. radiars, radiars, etc., etc., or or non-warranty non-warranty damage damage the the wed wed vehicle vehicle will This result. bracket is only warranteed the original installation. Installing This This used bracket bracket bracket is is only only another warranteed warranteed vehicle is the the not original original recommended installation. installation. and Installing Installing will void a the used used warranty. bracket bracket on on another another vehicle vehicle is is not not recommended recommended and and will will void void the the warranty. warranty.

3 Fig.C Fig.D Fig.E 1. Important: please use all supplied bolts and parts and read all instructions carefully bee beginning this installation. The majority of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin the installation. Start by removing 13 plastic fasteners attaching the radiar cover the fascia and core support (Fig.C). 2. On both sides, remove two 10mm bolts holding the headlight (Fig.D). 3. On both sides, lift up on the rear mounting point of the headlight and pull ward remove the headlight (Fig.E). Note: unplug the three plastic plugs bee removing the headlight. Fig.F Fig.G Fig.H 4. On both sides, remove two pop fasteners and one 10mm bolt from the headlight opening (Fig.F). 5. On both sides, remove one 8mm bolt attaching the fascia the fender (Fig.G). 6. Now, remove 19 plastic fasteners and three 10mm bolts attaching the center splash shield, the side splash panels and the lower fascia the underside of the car (Fig.H). 7. Disconnect the fog lights (if the vehicle is so equipped). 8. Pull ward on the fascia remove it. 9. Temporarily remove the bumper core by removing two 12mm (head) bolts and one 12mm (head) nut from each side (Fig.I). 10. Next, trim off the metal tabs at each side of the botm of the Fig.I Fig.J bumper core, until they are flush with the botm of the bumper core (Fig.J). All illustrations and specifications contained herein are based on the latest inmation available at the time of publication approval. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

4 Fig.K Fig.L Fig.M 11. On both sides, remove one 14mm bolt attaching the frame support the botm of the frame rail (Fig.K) 12. On both sides, position one of the supplied 1" x ¾" pipe spacers over the lower mounting hole at each end of the main receiver brace (Fig.L). 13. Position the main receiver brace under the frame rails, so that the pipe spacers align the holes the bolts you removed in step 11. On both sides, bolt through the main receiver brace, pipe spacer, frame support and in the botm of the frame rail (Fig.M) with the supplied 10mm x 1.25 x 50mm bolts. Tighten the two bolts the rque specifications at the botm of these instructions. Then, check ensure that the p of the main receiver brace is directly against the botm of both frame rails. Fig.N Fig.O Fig.O Fig.P 14. On both sides, use the upper mounting point on the outside of the main receiver brace as a template and drill a ½" hole through the botm of the frame rail (Fig.N). 15. On the driver side only, remove the two 10mm bolts attaching the air box the side of the frame rail (Fig.O). Then, position the air box off the side (Fig.P). Fig.Q Fig.R Fig.S rear bolt use a flat washer 16. On both sides, position one of the 1¾" x 7" backing plates inside the frame rail so that the holes in the plate align the existing hole approximately 6" inside the frame rail and the ½" hole you drilled in step 14 (Fig.Q). 17. On both sides, bolt each backing plate the main receiver brace and the frame rail use two of the supplied ½" x 1¾" carriage bolts, flat washers and lock washers on each side (Fig.R). Note: use the flat washers only on the rear bolts (Fig.S). All illustrations and specifications contained herein are based on the latest inmation available at the time of publication approval. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

5 Fig.T Fig.U Vertical rib Fig.V 18. Tighten all remaining bolts the rque specifications at the botm of these instructions. 19. Replace the bumper core (step 9) and the air box (step 15). 20. Attach the main receiver brace the bumper core on both sides, use one of the supplied 1½" x 2½" backing plates and ½" x 2½" bolts, lock washers and nuts bolt through the existing hole in the bumper core and the pre-drilled hole at the inside of the main receiver brace (Fig.T, U). Note: position the backing plate on the front side of the bumper core. 21. Torque the two bolts the rque specifications at the botm of these instructions. 22. Bee reinstalling the fascia, trim it on both sides, so that the removable front bracket arms can extend through the grill. On the '07-'08 Hyundai Enurage: mark the two horizontal ribs 2-3/8" back from the vertical rib shown in Figure V, and trim back the next vertical rib, as shown in Figure V. On the '06-'07 Kia Sedona: trim the fascia using the yellow lines in Figure W as a guide. 23. Reassemble the splash shields and fascia, reversing steps 1 Fig.W through Insert the removable front bracket arms in the front receiver braces, and secure them in place with the supplied 5/8" draw pins and spring pins (Fig.W). 25. Attach the 8" safety cables with the cable connecrs (Q-Links) the front of the receiver braces (Fig.X). 26. Attach the ends of the 8" safety cables the w vehicle's safety cables. 27. Install the w bar the mounting bracket according the manufacturer's instructions. Fig.X STANDARD BOLTS Thread Size Grade Torque 5/ ft./lb. 3/ ft./lb. 7/ ft./lb. 1/ ft./lb. 5/ ft./lb. BOLT TORQUE REQUIREMENTS Note: The rque values represented below are intended as general guidelines. Torque requirements specific applications may vary. Roadmaster does not warrant this inmation be accurate all applications and disclaims all liability any claims or damages which may result from its use. METRIC BOLTS Thread Size Grade Plated / Unplated 8mm ft./lb. 18 ft./lb. 8mm ft./lb. 18 ft./lb. 10mm ft./lb. 36 ft./lb. 10mm ft./lb. 35 ft./lb. METRIC BOLTS Thread Size Grade Plated / Unplated 12mm ft./lb. 65 ft./lb. 12mm ft./lb. 61 ft./lb. 12mm ft./lb. 60 ft./lb. 14mm ft./lb. 97 ft./lb. All illustrations and specifications contained herein are based on the latest inmation available at the time of publication approval. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.