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For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) 

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Assembly Instructions 

 40890 

*PLEASE READ ALL INSTRUCTIONS AND WARNINGS PRIOR TO ASSEMBLING, 

INSTALLING, AND USING THIS PRODUCT* 

Warning 

 

Always check for wires, fuel tanks and lines, brake lines and other important vehicle 
functionality items prior to drilling and installing all products. 

Tools Needed 

3/4

 Socket and Wrench 

9

/16” Socket and Wrench

 

5/16” Allen Hex

 

Phillips Driver 

 

Table of Contents

 

Parts List  ................................................................................................................................... 3 
Hardware  ................................................................................................................................. 4 

Assembly Instructions 

Step 1 

 Measure Distance Between Feet  ............................................................................ 5 

Step 2 

 Assemble Side Channels  .......................................................................................... 5 

Step 3 

 Assemble Rack  ...................................................................................................... 6-7 

Step 4 

 Assemble Rear Roller Bar  ........................................................................................ 8 

Step 5 

 Install Wind Deflector  .............................................................................................. 9 

Before You Begin 

 

Read all instructions. 

 

Be sure to put BH-821 sealant along swage joints and all threads connecting tubes 
together. This is to help with water getting into the tubing and causing rust issues. 

 

During installation onto vehicle, place sealant around all threads entering cargo area and 
between the rubber spacer and roof of vehicle to prevent water from leaking into cargo 
area. 

Summary of Contents for 40890

Page 1: ...Assembly Guide 40890 Kargo Master Rancho Cordova CA 95742 800 343 7486 CustomerService KargoMaster com DATE ______________...

Page 2: ...Phillips Driver Table of Contents Parts List 3 Hardware 4 Assembly Instructions Step 1 Measure Distance Between Feet 5 Step 2 Assemble Side Channels 5 Step 3 Assemble Rack 6 7 Step 4 Assemble Rear Rol...

Page 3: ...For Technical Support Call 800 343 7486 Monday Friday 7AM 4 PM PST Page 2 Assembly Instructions 40890...

Page 4: ...For Technical Support Call 800 343 7486 Monday Friday 7AM 4 PM PST Page 3 Assembly Instructions 40890 Parts...

Page 5: ...For Technical Support Call 800 343 7486 Monday Friday 7AM 4 PM PST Page 4 Assembly Instructions 40890 Hardware 18 40890...

Page 6: ...the rack Transit Roof Shown Step 2 Assemble Side Channels Assemble side channels using the front side channel and the rear side channel It does not madder which side the combination of the two will go...

Page 7: ...istances measured from step one to approximate where the cross bars should go Do not assemble any part of the rear roller bar assembly Once crossbars are in desired position bolt caps to crossbars usi...

Page 8: ...7486 Monday Friday 7AM 4 PM PST Page 7 Assembly Instructions 40890 Bolt front hoop to both side rails using 1 2 x 2 1 4 button head 1 2 flat washer and a 1 2 nyloc nut Be sure to place BH 821 along th...

Page 9: ...r bar with bushings to the roller bar side assembly using 3 8 oversize washer and 3 8 x 2 1 2 heax head bolt Do not TIGHTEN Bolt both roller bar side assemblies with the rear roller bar to the ends of...

Page 10: ...d Deflector Place wind deflector along the front hoop Some adjustment may be needed once vehicle is driven to minimize road noise Position clamp so it hooks in the slot of the wind deflector and goes...

Page 11: ...mbly Instructions 40890 Follow the mount kit instructions in the mount kit box to finish the installation Some adjustment on the wind deflector may be needed after driving and evaluating the wind nois...

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