THUMPER FAB TF041601 Can-Am Defender Headache Rack Installation Guide

THUMPER FAB TF041601 Can-Am Defender Headache Rack

Product Information

Product Installation Instructions

Install Accent Panel

1. Fasten the accent panel (2) to the headache rack (1) using 8 of the M8-1.25x20mm flange bolts (B).
2. Thread all 8 bolts into the threaded bungs before tightening evenly with a 13 mm socket.

Install Winch

1. Remove the winch from the supplied box and slide it into place under the winch cover plate, making sure the winch cable is facing the hole in the winch cover plate for the fairlead mount.

Install Fairlead

1. Run the winch cable through the hole in the winch cover plate and through the fairlead to prepare for fastening the fairlead to the winch cover plate. Be careful not to pinch the cable.
2. Fasten the fairlead to the winch cover plate using the provided hardware in the winch box.

Fasten Winch to Winch Mount Plate

1. Fasten the winch to the winch mount plate using the 4 X M6-1.0 x16mm flange bolts (A) and a 10mm socket ratchet.

Install Headache Rack

1. Raise the bed to the fully open position to prepare for placement and installation of the headache rack.
2. Hold the headache rack into place and use the 4 M8-1.25 x 45mm (C) flange bolts and a 13mm socket to fasten the headache rack to the upper holes in the roll cage. Do not fully tighten.
3. Thread the remaining 4 M8-1.25 x 20mm flange bolts (B) into the lower holes provided in the factory roll cage.
4. Once all 8 X M8-1.25 flange bolts (B and C) have been started, use the 13mm socket to tightly fasten the headache rack.

PARTS

Hardware Kit
A| 4| M6-1.0 x 16mm Flange Bolt
B| 12| M8-1.25 x 20mm Flange Bolt
C| 4| M8-1.25 x 45mm Flange Bolt

TOOLS

• Ratchet
• 13mm Socket
• 10 mm Socket

BEFORE YOU BEGIN

• If you do not feel comfortable installing your Thumper Fab HEADACHE RACK, please see your nearest CAN-AM Dealer for installation.

INSTALLATION INSTRUCTIONS

Install Accent Panel

• Fasten the accent panel (2) to the headache rack (1) using 8 of the M8-1.25x20mm flange bolts (B). Thread all 8 the bolts into the threaded bungs before tightening evenly with a 13 mm socket (FIG 1).

Install Winch

• Remove the winch from supplied box and slide it into place under the winch cover plate making sure the winch cable is facing the hole in the winch cover plate for the fairlead mount (FIG 2).

Install Fairlead

• Run winch cable through hole in winch cover plate and through fairlead to prepare to fasten the fairlead to the winch cover plate. Be careful not to pinch cable (FIG 3).

Fasten Fairlead

• Fasten the fairlead to the winch cover plate using the provided hardware in the winch box (FIG 4).

Fasten Winch to Winch Mount Plate

• Fasten the winch to the winch mount plate using the 4 X M6-1.0 x16mm flange bolts (A) and 10mm socket ratchet to attach the winch to the winch mount plate (FIG 5).

Install Headache Rack

• Raise the bed to the fully open position to prepare for placement and installation of the headache rack (FIG 6).

Install Headache Rack

• Hold the headache rack into place and use the 4 M8-1.25 x 45mm (C) flange bolts and 13mm socket to fasten the headache rack to the upper holes in the roll cage. Do not fully tighten (FIG 7).
• Thread the remaining 4 M8-1.25 x 20mm flange bolts (B) into the lower holes provided in the factory roll cage. Once all 8 X M8-1.25 flange bolts (B and C) have been started, use the 13mm socket to tightly fasten the headache rack (FIG 8).

Winch Wiring

• Please refer to wiring instruction contained in the winch box for complete detailed instructions for proper wiring of winch.

Install Cube Lights (Optional)

• Attach cube lights to the winch mount plate using the hardware provided in the cube light box (FIG 9).

The installation of products sold or manufactured by Thumper Fab including, but not limited to suspension components such as lift kits, control arms, frame stiffener kits, roofs, roll cages, and tires that exceed the original specifications for the vehicle, may change the vehicle’s center of gravity and handling characteristics both on- and off-road. You are aware that the installation of tires that are larger than original vehicle specifications may reduce the effectiveness of the braking system. Use of these products may place added stress to the original factory vehicle components which could cause them to weaken or possibly fail.

Products sold or manufactured by Thumper Fab are intended for off-road use only. Operation of a vehicle modified with these products on a road could result in serious bodily injury or death, and such operation may violate the laws of your state or municipality. You agree to operate your vehicle exclusively in the manner intended by the vehicle manufacturer. You agree that failure to safely and reasonably operate your vehicle could result in serious bodily injury or death, and that, as a result of installation of this product(s) to your vehicle, extreme care must be taken to prevent vehicle rollover or loss of control, which may be more likely to occur as a result of said modifications. You will avoid unsafe maneuvers, including sudden sharp turns or other abrupt maneuvers, which could make a vehicular accident more likely. You understand that Thumper Fab is not responsible or liable for any damages or any injuries to yourself or your passengers that could occur upon possible accidents due to driver error, incorrect installations, bad judgment, incompatibility with other aftermarket accessories or natural disasters to the fullest extent allowable by law. You will have all vehicle occupants fasten seatbelts, if equipped, and wear proper safety equipment, such as DOT approved helmet and eye protection prior to operating the vehicle. You understand and acknowledge that failure to wear proper safety equipment may increase the risk of serious bodily injury or death to yourself and any passengers.

Proper installation of products sold or manufactured by Thumper Fab requires knowledge of the factory recommended procedures for removal and installation of original equipment components. Installation of these products without proper knowledge and experience may affect the performance of these components and the safety of the vehicle and cause serious bodily injury or death. It is strongly recommended that a certified mechanic familiar with the installation of similar components perform the product(s) installation.

Prior to installing any products sold or manufactured by Thumper Fab, you will perform or cause to be performed an inspection of their vehicle to confirm its condition is suitable for the installation of these products. A proper inspection of the vehicle includes confirmation that the vehicle has not been in a collision and is free of corrosion. If the vehicle is suspected to have been in a collision or misused, or is otherwise unsuitable for modification, you will not install the product(s). You will continue to inspect the vehicle prior to each use to confirm its condition is suitable for its intended use, and you acknowledge that the failure to do so may result in serious bodily injury or death, as well as damage to the vehicle itself.

You will install any warning labels provided with the product so it may be prominently seen by yourself and all passengers. You will notify all passengers of the modifications performed to your vehicle prior to operation. Insurance companies may handle coverage of a modified vehicle differently. Please check with your insurance carrier prior to modifying the vehicle to ensure your coverage remains sufficient. Installation of this product(s) may void your vehicle warranty. If this is a concern, please check with the manufacturer or dealer before purchase or installation of this product(s).

If you are enjoying your Defender Headache Rack, check out these other Thumper Products:

• Defender Wireless Phone Charger Dash Mount TF040904

Accent Light Covers for the Defender ELITE EDITION Winch Ready Rear Bumper TF040601.F-PB

• Defender Nerf Rails (3-seat)
• TF040702-BK

Contact

Thumper Fab

• 5103 Elysian Fields Rd, Marshall, Tx 75672
• Customer Service: 903-472-0928
• www.thumperfab.com

References

• Thumper Fab - UTV Accessories

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