Witter ZX404 User Manual

Torque Range 0-220 Nm
24mm x 1
Tools required for initial assembly:
+
x 2
CYCLE CARRIER SYSTEMS
ASSEMBLY AND USER INSTRUCTIONS v2
ZX404 Cycle Carrier
4x
ASSEMBLY AND USER INSTRUCTIONS v2
GB
Whenever this product is used the following information must be taken into
consideration:
The cycle carrier is a safe product IF used correctly, whereas if it is used incorrectly
it can cause damage to you, your vehicle and anyone driving behind you.
Rear cycle carrier
for mounting onto
a ange type towbar.
ATTENTION – SAFETY REQUIREMENTS
-The correct installation and use of this cycle carrier is the sole responsibility of the user.
-Weight and maximum capacity of “ZX404” bike racks:
Cycle carrier weight 19.6kg (excluding base plate) MAX cycle weight 20 kg
- 4 bikes, max. total capacity 65 kg
-Never exceed the vehicle manufacturer’s static nose weight.
-Never use an automatic car wash system when the carrier is mounted.
-The combined weight of the bike rack and the load must never exceed the permitted capacity.
-Remove from the transported bikes children’s seats, transport baskets, rain covers or other
elements that could get lost or increase the air resistance.
-The bike rack is only suitable for transporting bicycles.
-Before leaving, check that the rear lights of the vehicle and carrier function correctly.
-Ensure that the bike rack is fitted correctly on the cycle carrier base plate and that the bikes are
secured as instructed.
-When on the road, respect the highway code speed limits and pay attention to
the road conditions to prevent jolts.
-Be aware that the loaded bike rack may change the driving characteristics of the car while
braking, during windy conditions and whilst cornering.
-To avoid damage, if the boot lid is equipped with an automatic opening function,
use this function with care.
-Check all the bike rack fixing elements after a short while, then at regular intervals whilst on
your journey.
-Take care when reversing and parking because of the greater length of the car.
-Check the distance between the bike rack, the bikes and the exhaust pipe(s) to avoid heat
damage.
-To increase road safety and to reduce fuel consumption, remove the bike rack when not in use.
-Modifications to the bike rack and its components are not permitted.
-Immediately replace any worn or damaged parts using only original spare parts.
-The bike rack can be cleaned using warm water and/or car shampoo.
-Store the bike rack in dry conditions at moderate temperatures.
-The manufacturer is not responsible for damage caused by improper use of this product, nor for
any objection made by the competent authorities with regard to the highway code.
-The manufacturer shall only be responsible for manufacturing defects in the bike rack and
accessory components.
km/h
110
Supplied.
24 mm

Witter ZX404 Specifications

General

Brand	Witter
Model	ZX404
Category	Bicycle Accessories
Language	English

Summary

Cycle Carrier Systems

ZX404 Cycle Carrier

Assembly and user instructions for the ZX404 Cycle Carrier model.

ATTENTION – SAFETY REQUIREMENTS

Tilt Latch Play Adjustment

Tilt Latch Play Adjustment

Adjusting the tilt latch feature for optimal performance and minimizing play in the mechanism.

Maintenance

Periodic checks, bolt tightening, and lubrication of the tilt mechanism.

Release Cycle Clamp Arms

How to release cycle clamp arms

Instructions on releasing the cycle clamp arms using the ratchet levers.

Towbar Nose Weight Limit

Check towbar nose weight limit

Verify the towbar's static nose weight limit before mounting the carrier.

Remove and discard old bolts

Discard existing M16 bolts, washers, and nuts when attaching the carrier.

Tail-gate Clearance Adjustment

Adjusting carrier height for tail-gate clearance

Lowering the carrier using upper holes for tail-gate access when tilted.

Ratchet Strap and Clamp Arm Operation

How to operate ratchet straps

Securing wheels using straps and buckles on the carrier.

How to Tension cycle clamp arms

Tensioning cycle clamp arms with ratchet levers, avoiding over-tightening.

Installation - Critical Fasteners

Tighten M16 nuts fully

Ensure M16 nuts are tightened to 214Nm for secure mounting.

Ensure electrical cable is not stressed

Ensure electrical cable is not stressed or pulled too tight for proper function.

Carrier Positioning and Safety Pins

Positioning carrier in position

Slotting the groove onto the pin and hooking the base plate to hold the carrier.

Ensure safety pins are inserted

Confirm that safety pins are fully inserted and closed before proceeding.

Electrical Connection and Bike Mounting

Attach 13 pin plug to socket

Connect the 13-pin plug to the vehicle's electrical socket.

Positioning and fixing bikes

Instructions for placing and securing bikes on the carrier using clamp arms.

Bike 1: Place the heaviest bike

Place the heaviest bike first, closest to the vehicle, and secure.

Bike 2: Fits in second set of locators

Place Bike 2 in the second set of locators and secure with clamp arm.

Bike 3: Fits in third set of locators

Place Bike 3 in the third set of locators and secure with clamp arm.

Bike 4: Fits in outer locators

Place the smallest/lightest bike in outer locators and secure.

Lighting Board and Rail Installation

Mount the lighting board

Securing the lighting board to the carrier using specified bolts and nuts.

Push plastic end caps

Insert plastic end caps into the cycle rails for finishing.

Secure the rails

Mount and secure the rails with washers and nuts underneath the sub-frame.

Tilt platform for bolt access

Tilt the platform to access bolts located underneath during mounting.

Wheel Locator and Clamp Arm Attachment

Position wheel locators

Place wheel locators on the rail, aligning bolts with the channel and cutout.

Attach protective rubber

Attach protective rubber to clamp arms, ensuring it does not impede the ratchet system.

Attach clamp arms

Fix clamp arms to the carrier support frame using thumb nuts and bolts.

Seat thumb nut and bolt

Ensure thumb nuts and bolts are seated properly, avoiding over-tightening.

Number Plate and Cable Management

Number plate fitting warning

Avoid screwing the number plate through the back-plate to prevent cable damage.

Lighting Cable Routing and Safety

Route lighting board cable

Carefully route and secure the lighting board cable with ties, ensuring no damage.

Prevent cable snagging

Ensure the electrical cable does not hang low enough to catch the floor while driving.

Final Checks and Bike Positioning

Check light function

Verify that all vehicle lights connected to the carrier are functioning correctly.

Tilting Carrier Safety

Care when tilting carrier

Exercise caution when tilting the carrier to avoid head and finger injury.