THUMPER FAB TF041901 Can Am Defender Bed Rack User Manual
- June 12, 2024
- THUMPER FAB
Table of Contents
THUMPER FAB TF041901 Can Am Defender Bed Rack
Product Information
Product Name: Can-Am Defender Bed Rack
SKU: TF041901
Manufacturer: Thumper Fab
Address: 5103 Elysian Fields Rd, Marshall, TX 75672
Customer Service: 903-472-0928
Website: www.thumperfab.com
Version: 0622
Parts Included:
- Rear Column – DR
- Rear Column – PA
- Front Column – DR
- Front Column – PA
- Light Cube Cover (2)
- Lower Main Rail – DR
- Lower Main Rail – PA
- Middle Rail – DR
- Middle Rail – PA
- Upper Main Rail – DR
- Upper Main Rail – PA
- Sway Support – DR
- Sway Support – PA
- Rear Brace
- Upper Rack – REAR
- Upper Rack – FRONT
- Upper Rack Accent Panel (2)
- Upper Rack Connection Bracket (2)
Product Usage Instructions
Before You Begin
If you do not feel comfortable installing your Thumper Fab Bed, please
contact customer service for assistance.
Installation Instructions
Assemble Each Side
These instructions will be followed for driver’s and passenger’s side, and
they can be completed consecutively or individually. Separate and stage
materials on a table. Tools Required:
None specified
Hand Tighten Hardware for the Side Panels of Bed Rack
Assemble lower main rail – DR, rear column -DR, front column DR, middle
rail – DR, and upper main rail – DR. Use 16 X M8-1.25 x 55mm flange bolts, 12
X M8-1.25 x 20mm flange bolts, and 28 X M8-1.25 x flange lock nuts to loosely
attach the side panel of the bed rack. Tools Required:
None specified
Insert Washers
Fit the spacers in the four corners of the bed using the factory-provided
mounting holes. Once securely fit, raise the bed for easier fastening of the
hardware. Tools Required:
None specified
Secure Spacers using Bolt Assembly in Front Corners of Bed
Tighten the following in order: 1 X M8 x 1.25 x 30mm flanged bolt, 1 X
Spacer, 1 X 5/16 washer, and 1 X M8-1.25 flanged lock nut. Tighten on both
front corners of the bed. Once the front two mounting fasteners are hand
tight, lower the bed for the remainder of the installation. Tools Required:
7/16 Socket & 7/16 Wrench
Remove the Two Middle Rail Screws to Fasten Rear Brace
Remove the 4 X M8-1.25 x 55mm Flange Bolts and 4 X M8-1.25 flange lock nuts
to be able to install the rear brace. Tools Required:
None specified
Fasten Rear Brace
Connect both sides using 4 X M8-1.25 x 55mm flange bolts and 4 X M8-1.25
flange lock nuts. Hand tighten. Tools Required:
None specified
PARTS
HARDWARE
BEFORE YOU BEGIN
If you do not feel comfortable installing your Thumper Fab Bed Rack please see your nearest Can-Am® Dealer for installation.
INSTALLATION INSTRUCTIONS
Assemble Each Side
These instructions will be followed for drivers and passengers side, they can
be completed consecutively or individually. Separate and stage materials, this
will be easiest on a table (FIG 1). FIG 1 – Separate & Stage Materials for
Driver and Passengers Side
TOOLS
- 10mm Socket
- 13mm Socket
- 7/16” Socket
- 10mm Wrench
- 13mm Wrench
- 7/16” Wrench
- Ratchet
- Rubber Mallet
Hand Tighten Hardware for the Side Panels of Bed Rack
Assemble lower main rail – DR (6), rear column -DR (1), front column – DR (3),
middle rail – DR (8) and upper main rail – DR (10). Using 16 X M8-1.25 x 55mm
flange bolts (C), 12 X M8-1.25 x 20mm flange bolts (D) & 28 X M8-1.25 x flange
lock nuts (E), loosely attach side panel of bed rack (FIG 2).
Once loosely assembled, place side rails on top of Defender Bed rail for mounting (FIG 3)
Insert Washers
Using factory provided mounting holes fit the Spacers (L) in the four corners
of the bed. Once fit securely, raise the bed for easier fastening of the
hardware (FIG 4).
Secure Spacers using Bolt Assembly in Front Corners of Bed
Using the 7/16” socket & 7/16” wrench, tighten in this order: 1 X M8-1.25 x
30mm flanged bolt (J), 1 X Spacer (L), 1 X 5/16” washer (K) & 1 X M8-1.25
flanged lock nut (E) tighten on both front corners of the bed. Once front 2
mounting fasteners are hand tight, lower bed for remainder of install (FIG 5).
Remove the Two Middle Rail Screws to Fasten Rear Brace
Remove the 4 X M8-1.25 x 55mm Flange Bolts (C) and 4 X M8-1.25 flange lock
nuts (E) to be able to install the rear brace (14) (FIG 6).
Fasten Rear Brace
Using the rear brace (14), connect both sides using 4 X M8-1.25 x 55mm flange
bolts (C) and 4 X M8-1.25 flange lock nuts (E) hand tighten (FIG 7).
FIG 7 – Connect the Rear Brace to the Bed Rack using a 13mm Socket and 13mm Wrench
Install Upper Basket
Place the upper rack – FRONT (16) on top of the bed rack towards the front of
the unit. Secure into place using 2 X M8-1.25 x 20mm flange bolts (I) & 2 X
M8-1.25 flange lock nuts (J). Next, place the upper rack – REAR (15) behind
the upper rack – FRONT (16) using 2 X M8-1.25 x 20mm flange bolts (D) & 2 X
M8-1.25 flange lock nuts (E)(FIG 15). Once hand tight install sway supports
(12 & 13) using 4 X M8-1.25 x 20mm flange bolts (D) and 4 X M8-1.25 flange
lock nut (E) (FIG 16).
Fasten front and rear racks from the underside using 3 X M6-1.0 x 16mm flange bolts (A) and 3 X M6-1.0 flange lock nuts (B). Using 10mm socket and 10mm wrench to fasten the upper rack connection brackets (18) and the upper rack accent panels (17) with 8 X M6-1.0 x 16mm flange bolts (A) and M6-1.0 lock nuts (B). Tighten all bed rack bolts using 13mm Socket and 13mm Wrench (FIG 17).
ACCESSORIES
TOOLS – Rear Door
- 14mm Socket
- 9/16” Socket
- 1z4mm Wrench
- 7/8” Wrench
- 9/16” Wrench
- 11/16” Wrench
ACCESSORY INSTALLATION INSTRUCTIONS
Optional Spare Tire Carrier Install
Using 8 X M8-1.25 x 20mm flange bolts (A) and 8 X M8-1.25 flange lock nuts (B)
assemble the tire adjuster mount brace (7), tire height adjuster (8), and tire
diameter adjuster mount (9) (FIG 17).
Using the remaining 8 X M8-1.25 x 20mm flange bolts (A), and 8 X M8- 1.25
flange lock nuts (B) to fasten the frame mount assembly (6) to the tire mount
assembly (5). Use the 2 X M12-1.5 hex cap screws (C) and 2 X M12-1.5 wheel
nuts (D) to attach tire to mount assembly (5)(FIG 18).
Optional Rear Door
Remove the 2 rear middle rail bolts on both sides. Connect latch A (11), latch
B (12) & latch C (13) with slots centered use 2 X M6-1.0 x 16mm flange bolts
(A) and 2 X M6-1.0 lock nuts (B) and 10mm socket and 10mm wrench. Insert the
new piece (latch) in to the driver side rear column (1), loosley fasten using
4 X M8-1.25 x 20mm flange bolts (H) and M8-1.25 flange lock nuts (I) (FIG 19
)
Secure Hiem Joints
Thread 2 X 3/8”-24 hiem joints (J) and 2 X 3/8”-24 jam nuts (K) into weldnuts
provided in mount hinge (14). Do Not Tighten!! Using the 6 X M8-1.25 x 20mm
flange bolts (H) and 6 X M8-1.25 flange lock nuts (I) fasten the mount hinge
(14) to the passenger rear column using a 13mm socket and 13 mm wrench (FIG
18).
Installation of Rear Door
Place the rear door (10) into place on the hiem joint and test fit door
swinging path using 2 X 3/8-16 x 1-1/2” flange head bolts (L) and 2 X 3/8-16
lock nuts (M). Adjustment of hiem joints (J) will need to be performed to
align the retractable spring plunger (N) with the latch assembly, this may
take several attempts, back out lower hiem and screw in upper hiem to adjust
door height at latch (FIG 19).
Retractable Spring Plunger
Install the retractable spring plunger (N). Once door is aligned properly
using adjustment of hiem joints (J) the door should easily swing and close
properly. Tighten all remaining hardware and install 2 X plastic tub- ing
plugs in the end of the driver side door (O) using rubber mallet (FIG 20 & 21
).
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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 offroad 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).
Thumper Fab
5103 Elysian Fields Rd, Marshall, TX 75672
Customer Service: 903-472-0928
www.thumperfab.com