This document describes the Halfords roof bar system, designed for specific vehicle models to expand their carrying capacity. The system is tested to DIN 75302 standards and has a maximum load capacity of 50kg. It is intended for use with Halfords foot pack PACK 2 (725428).

Function Description:

The Halfords roof bar system provides a secure platform on the roof of a vehicle for transporting additional luggage or specialized equipment. It consists of two crossbars that attach to the vehicle's roof using a foot pack system. The system is designed to be robust, allowing for the transportation of items that cannot fit inside the vehicle, such as bicycles, skis, or large luggage boxes. The maximum load capacity of 50kg includes the weight of the roof bars themselves (approximately 4kg), meaning the additional load should not exceed 46kg. The system is engineered to distribute weight evenly across the vehicle's roof, ensuring stability and safety during transit.

Usage Features:

The installation process involves several key steps, starting with the assembly of the foot pack onto the roof bars. The end caps of the bars are removed, covers are taken off the feet, and the foot pack is slid onto the bar without tightening initially. The end caps are then replaced, leaving the feet covers off for subsequent steps.

Specific dimensions for positioning the roof bars (X and Y measurements) and the foot pack (A and B measurements) are provided for various car models, including AUDI A3 Sportback, VOLKSWAGEN Polo IV (3-door and 5-door), VOLKSWAGEN Polo V, and FORD Fiesta. These measurements are crucial for correct and safe installation. For example, the AUDI A3 Sportback (2004-2013, 5-door) requires an X measurement of 97 cm, a Y measurement of 93 cm, an A measurement of 16.5 cm, and a B measurement of 68 cm. The tightening torque for the fixings is specified as 6Nm, which should be applied alternately to ensure even pressure.

The manual emphasizes the importance of adhering to these dimensions and contacting the retailer if there is any doubt. The installation involves placing the assembled roof bars onto the vehicle's roof, ensuring the feet are correctly positioned according to the model-specific measurements. For certain models, like the Volkswagen Polo (6R_) and Ford Fiesta VII (5-door), specific instructions for measuring A and B are provided. Similarly, for Volkswagen Polo (9n) 3-door and 5-door models, there are distinct instructions for measuring A and B. After positioning, the fixings are tightened alternately to the specified torque.

Once installed, it is critical to check the security of the roof bars and the load. The manual advises against exceeding the total weight permitted on the vehicle roof and warns that the roof bars will affect fuel economy. Users should be mindful of low clearances, such as garages or multi-storey car parks, especially when carrying high loads like bicycles. Driving through automatic car washes with the load carrier mounted is not recommended. The system's use will affect the vehicle's driving and braking characteristics, and speed should be adjusted accordingly, with a recommended maximum speed of 65 mph when transporting a load. Large, flat objects like surfboards or boats should be secured carefully to prevent damaging aerodynamic forces, and multiple surfboards should be stacked, not carried side-by-side, and secured independently. Kayaks and canoes should be secured upright to the bars and to the front and rear of the vehicle.

Maintenance Features:

Regular maintenance is crucial for the longevity and safe operation of the Halfords roof bar system. Before driving and at regular intervals during a journey, all securing screws, clamping devices, and foot attachments must be checked and fully tightened. After covering a short distance, all securing devices of both the load and the load carrier must be re-checked and tightened as required, with the frequency depending on road conditions.

To prevent damage or discolouration to the vehicle's paintwork under the foot pack rubber, it is recommended to clean the load bar feet and the vehicle roof prior to fitting. The load bars should also be removed at regular intervals to repeat this cleaning process. The roof bars should be kept clean and properly maintained, especially during winter months, to remove dirt and salt. Bolts, screws, and nuts should be lubricated at suitable intervals, and a spray lubricant can be used to keep any lock barrels working freely.

For disassembly, the installation steps should be performed in reverse. The manual also advises retaining the provided Hex key and instructions safely with the car owner's manual for future reference. It is important to note that the load carrier is specifically designed for the car model, and spare parts from other products should not be used without checking with the retailer.

Halfords KIT 045 - Page 7

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