THULE XSPORTER PRO 500XT Truck Rack Instruction Manual

XSPORTER PRO 500XT/500XTB
= North American
PARTS INCLUDED

5067034_09

XSPORTER PRO 500XT Truck Rack

WARNINGS / LIMITATIONS:

– This system has been designed with a maximum load capacity  of 450 lbs. Do not exceed vehiclemanufacturer’s load limits.
– If used in conjuction with another type of load carrying system the  lower weight capacity of the two systems should befollowed.
– Tie down front and rear of all long loads to the vehicles bumpers for safe transport.
– Excessive rust in bed decreases carrying capacity and could result in system failure.
– Vehicles with bed liners could require modifications.
Read through the instructions prior to begining installation.
– Do not load the rack with items  that block the Center HighMounted Stop Lamp (CHMSL) when the vehicle is inmotion.

450 lbs rack weight limit at position 15 (half height) or lower
250 lbs rack weight limit at position 29 / full height
Check your vehicles truck bed rail capacity before loading.
Include product weight (57 lbs) when calculating your bedrail capacity.
Max. load = carrier weight + any fitted carrier accessories + weight of load itself.

Attach Saddles (B) to tops of Uprights (C) and secure with two 1 1/2″ Flat Head Cap Screws (A). Torque to 32 ft-lbs using 7/32″ Allen Key (D).
NOTE: Thread Flat Head Cap Screws by hand first to avoid cross threading bolt.
When tightening, ensure Allen Key is fully seated to avoid stripping.

On Base Assemblies (E/F/G/H), loosen QuickDials and insert pre-assembled Uprights with black Gear Rack facing towards QuickDial.
Make sure Base Assembly T-Bolts slide into Gear Rack channels.
TIP: While inserting Upright, slowly move QuickDial back and forth to help seat T-Bolt into Gear Rack Track.
Insert 5/8″ Button Head Cap Screws (H) through bottoms of Saddles and thread loosely into Square Nuts (I). Make sure flat sides of Square Nuts are facing down towards Saddles.

Slide Square Nuts at top of Saddle onto bottom Crossbar (J) t-slot. Make sure tapered side of crossbar is facing towards the truck cab.
Crossbar should remain loosely assembled for later adjustment.
Repeat at other side of Crossbar, and follow same steps for second Crossbar and Base Assembly.
See instructions p.1 for correct orientation of Crossbars and Base Assemblies.
NOTE: Crossbars will be fully secured to Saddles once Crossbar / Upright assemblies are installed and adjusted on truck.
NOTE: XK3 adapter required for Toyota Tacoma (not included).

1. Thread 3″ Button Head Cap Screws (K) loosely through front hole of Clamps (L).
2. Add T-Slides (N) to two of the Clamps by threading 3/4″ Socket Head Cap Screws (M) up through rear hole. Tighten fully using 5/16″ Allen Key (O). Front slot on T-Slide will index on 3″ clamp bolt.

Clean bedrails.
Position Shims (P) and entire front Crossbar assembly on bedrails as close to cab as possible.
Carefully align Shims under Crossbar bases.
TIP: Mount location is different for each bed design and may require adjustment to avoid interference with hardware mounting.

Place Clamp Foot (Q) on top of Clamp bolt. Slide Clamp onto Base top groove, with Clamp Foot under bedrail. Locate Clamp as close to upright as possible and hand tighten bolt. Repeat with second clamp, placing as far back on Base as possible, and hand tighten.
Repeat on other side of front Crossbar assembly using one standard clamp and one clamp equipped with T-Slide.
Using a tape measure, ensure Bases are spaced evenly off cab or end of bed. Tighten Clamp bolts to 10 ft-lbs using 7/32″Allen Key.
NOTE: Some bedliners may need to be modified. Cutting bedliners in area of mounting hardware may be necessary.
WARNING: Clamp spacing of less than 3″ (76.2mm) reduces rack load capacity. If truck bed design prevents 3″ Clamp spacing, move Base Assembly along bedrail until proper Clamp spacing is possible.

Position rear Crossbar assembly and Shims as close as possible to tailgate and repeat steps 6 + 7.
Using a tape measure, ensure equal front-rear Crossbar spacing and tighten rear Clamp bolts.
NOTE: Some accessories require a specific distance between crossbars. If installing secondary accessories, check accessory fit prior to positioning and securing.
Using tape measure, center Crossbars side-to-side at ends, and ensure Uprights are at 90-degrees.  Use 7/32″ Allen Key to secure Saddles to Crossbars and torque to 27 ft-lbs.Pre-assemble all load stops as shown.
Attach knob loosely.

Install load stops by inserting tab on underside of load stop and t-bolt into t-track on top of crossbar. Make sure both the tab and t-bolt have engaged the t-track before continuing.

Tighten knob firmly to set load stop position.

Insert End Caps (R) into Crossbar ends and secure with 14mm Socket Head Cap Screws (S). Do not over-tighten.

UInstallation of Crossbar Rubber Strips (T) is optional. To install, place rubber strip on the top Crossbar t-slot with ribbed side facing up. If Load Stops have been installed, Rubber Strips may be left off or cut to fit around Stops.
Starting at one end of Crossbar, insert end of Rubber Strip into t-slot by pushing down until Rubber Strip fully seats into slot. Continue across bar.

1. Install Lock Cylinders (V) into two Locking End Caps (U) by inserting Change Key (W) into Lock Cylinder and inserting Cyclinder into End Cap.
   Hold Cylinder in place and remove Change Key to complete install.
   NOTE: Ensure Cylinder is properly aligned with tabs in Cap before inserting.

2.  Install plastic Lock Plugs (Y) into remaining two End Caps.

3. Slide one Locking End Cap assembly into bottom of a front Upright. Secure in place by inserting and turning N-Series Key (X) 90-degrees.
   Repeat with second Locking End Cap on a rear Uptight. Finish by pressing remaining End Caps into remaining Uprights.
   Turn Lock Plugs 90-degrees to secure in place.

1. Install Lock Cylinders into two Locking Clamp Covers (Z) by inserting Change Key into Lock Cylinder and inserting Cylinder into Clamp Cover.
   Hold Cylinder in place and remove Change Key to complete install.

2.  Slide Locking Clamp Covers onto bottom of two Clamps equipped with T-Slides. Secure in place by inserting and turning N-Series Key (X) 90-degrees.

North American

THULE RACK GUIDELINES

When using Thule Load carriers and accessories, the user must understand the precautions. The points listed below will assist you in using the rack system and will encourage safety.

• For quality fits and safety, use only the recommended rack or accessory as stated in Thule’s current Fit Guide. Do not assume a rack will fit, always check the current Fit Guide when obtaining a new vehicle.

• The maximum load specified in the assembly instructions is not to be exceeded. However, this limit is always subordinate to the maximum load recommended by the manufacturer of the car itself. It is always the lower maximum recommended load that applies. Max roof load = load carrier weight + any fitted carrier accessories + the weight of the load itself.

• Always make sure all doors are open when mounting a roof rack system.
  Make sure all knobs, bolts, screws, straps, and locks are firmly attached, tightened and locked before every trip. Knobs, bolts, screws, straps and locks must be periodically inspected for signs of wear, corrosion, and fatigue. Check your load at stops during the trip to ensure continued fastening security.

• Check local and state laws governing projection of objects beyond the perimeter of a vehicle. Be aware of the width and height of your cargo since low clearance branches, bridges, and parking garages can affect the load. All cargo will affect the vehicle’s driving behavior. Never drive with any lock, knob or rack in an open or unlocked position. All long loads such as, but not limited to, sailboards, surfboards, kayaks, canoes, and lumber must be tied down front and rear to the bumpers or tow hooks of the vehicle.

• Remove your Thule rack and accessories when they are not in use and before entering automatic car washes.

• All locks must be turned and moved periodically to ensure smooth operation. Use graphite or dry lubricant to help this. Thule locks are designed to deter vandalism and theft but should not be considered theft proof. Remove valuable gear if your vehicle is unattended for an extended period. Place at least one key in the glove compartment.

• For safety to your vehicle and rack system, obey all posted speed limits and traffic cautions. Adapt your speed to the conditions of the road and the load being carried.

• Do not use Thule load carriers and accessories for purposes other than those for which they were designed. Do not exceed their carrying capacity. Failure to follow these guidelines or the product’s instructions will void the warranty.

• All loads must be secured using the provided straps.

• Consult with your Thule dealer if you have any questions regarding the operations and limits of Thule products. Review all instructions and warranty information carefully.

• Not for use on trailers or towed vehicles.

• Not for offroad use.

•  Keep bicycle tires away from hot exhaust.

THULE CAR RACK SYSTEMS LIMITED LIFETIME WARRANTY [EFFECTIVE JANUARY 1, 2006]
Register online at www.thule.com/warranty
THULE will warranty all THULE brand car rack systems and its accessories manufactured by THULE during the time that an original retail purchaser owns the product. This warranty terminates if a purchaser transfers the product to any other person.
Subject to the limitations and exclusions described in this warranty, THULE will remedy defects in materials or workmanship by repairing or replacing, at its option, a defective product without charge for parts or labor. In addition, THULE may elect, at its option, not to repair or replace a defective product but rather issue to a purchaser a refund equal to the purchase price paid for the product or a credit to be used toward the purchase of a new THULE load carrier system. No warranty is given for defects caused by normal wear and tear, cosmetic rust, scratches, accidents, unlawful vehicle operation, or modification of, or any types of repair of, a load carrier system other than those authorized by THULE. No warranty is given for defects resulting from conditions beyond THULE’s control including, but not limited to, misuse, overloading, or failure to assemble, mount or use the product in accordance with THULE’s written instructions or guidelines included with the product or made available to the purchaser.
In the event that a product is defective, the purchaser should contact the THULE dealer from whom the product was purchased or an Authorized Thule Service Center. If the dealer or Authorized Thule Service Center is not able to correct the defect, the purchaser should contact THULE in writing or by phone using the contact information listed at the bottom of this page. In the event that a product needs to be returned to THULE, a THULE technician at the address or telephone number listed below will provide the purchaser with the appropriate mailing address and any additional instructions. Please note that the purchaser will be responsible for the cost of mailing the product to THULE and that proof of purchase in the form of an original purchase invoice or receipt and a detailed description of the defect must be included in the mailing.
DISCLAIMER OF LIABILITY
REPAIR OR REPLACEMENT OF A DEFECTIVE PRODUCT OR THE ISSUANCE OF A REFUND OR CREDIT (AS DETERMINED BY THULE) IS A PURCHASER’S EXCLUSIVE REMEDY UNDER THIS WARRANTY. DAMAGE TO A PURCHASER’S
VEHICLE, CARGO AND/OR TO ANY OTHER PERSON OR PROPERTY IS EXCLUDED.
THIS WARRANTY IS EXPRESSLY MADE IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
THULE’S SOLE LIABILITY TO ANY PURCHASER IS LIMITED TO THE REMEDY SET FORTH ABOVE. IN NO EVENT WILL THULE BE LIABLE FOR ANY LOST PROFITS, LOST SALES, OR FOR ANY CONSEQUENTIAL, DIRECT, INDIRECT,
INCIDENTAL, SPECIAL, EXEMPLARY, OR PUNITIVE DAMAGES OR FOR ANY OTHER DAMAGES OF ANY KIND OR NATURE.
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT BE APPLICABLE.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

  Thule Inc. • 42 Silvermine Road • Seymour, CT 06483
Thule Canada Inc. • 710 Bernard • Granby QC J2J 0H6
North American
Consumer Service: Toll Free800-238-2388 /
Fax450-777-3615
•www.thule.com
Register online at
www.thule.com/warranty C7

References

• Thule | United States
• Bring your gear with confidence | Thule | United States

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