Aries Automotive 2549 User Manual
INSTALLATION INSTRUCTIONS
SPORT BAR
06-09 TOYOTA RAV4
PART #2549
PARTS LIST:
1 Sport Bar 4 12-1.75mm x 35mm Hex Head Bolts
1 Driver/Left Frame Mounting Bracket 2 12-1.75mm x 40mm Hex Head Bolts
1 Passenger/Right Frame Mounting Bracket 6 12mm Lock Washers
1 Driver/Left Mounting Bracket 10 12mm ID x 30.1mm OD x 3.1mm Flat Washers
1 Passenger/Right Mounting Bracket 4 12mm Hex Nuts
Passenger Side
Frame Mounting
Bracket
Driver Side
Mounting
Bracket
Passenger Side
Mounting
Bracket
Driver Side
Mounting
Bracket
PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS
CAREFULLY BEFORE STARTING INSTALLATION. CUTTING IS REQUIRED. ASSISTANCE IS
RECOMENNDED.
2. Starting under the front of the vehicle, remove the plastic splash guard and place it on a clean,
stable work area. IMPORTANT: Pay close attention to the specific location of all of the twopiece plastic clips and screws to make reinstallation easier. Use a small flat blade screwdriver
to gently pry up the plastic center pin to release the clips and remove the center pin and the
plastic housing.
3. Locate the (4) factory hex bolts securing the crossmember to the frame. NOTE: Only install
one Frame Mounting Bracket at a time and only remove the (3) factory hex bolts required to
install the Bracket, (Figure 1). Select the driver side Frame Mounting Bracket and bolt it into
position with the factory hex bolts. Snug the hardware but do not tighten at this time.
4. Select the driver side Mounting Bracket. Bolt the Mounting Bracket to the inside of the Frame
Mounting Bracket with the included (2) 12mm x 35mm Hex Bolts, (2) 12mm Lock Washers, (4)
12mm Flat Washers and (2) 12mm Hex Nuts, (Figure 2). Snug but do not tighten hardware at
this time. Repeat Steps 3 & 4 for the passenger side bracket installation.
5. Place the Sport Bar face down on a clean surface in front of the vehicle. NOTE: Use the
packing materials to protect the finish on the Sport Bar. With assistance, carefully position the
Sport Bar up to the Mounting Brackets. Attach the Sport Bar to Mounting Brackets using the
included (2) 12mm x 40mm Hex Bolts, (2) 12mm Lock Washers, (2) 12mm Flat Washers,
(Figure 2).
6. Level and adjust the Sport Bar and tighten all hardware.
Page 1 of 2 2/5/09 Rev 1(DP)
7. Hold the splash guard up into position and mark the location to cut the splash guard to clear
the Mounting Brackets, (Figure 3). IMPORTANT: To maintain strength, cut only what is
required to clear the Mounting Brackets. Once cut and trimmed for fit, reinstall the splash
guard using the factory hardware.
8. Do periodic inspections to the installation to make sure that all hardware is secure and tight.
To protect your investment, wax this product after installing. Regular waxing is recommended to
add a protective layer over the finish. Do not use any type of polish or wax that may contain abrasives
that could damage the finish.
For stainless steel: Aluminum polish may be used to polish small scratches and scuffs on the finish.
Mild soap may be used also to clean the Sport Bar.
For gloss black finishes: Mild soap may be used to clean the Sport Bar.
Driver Side Installation Pictured
Use the Factory Bolts
(2) 12mm x 35mm Hex Bolts
(2) 12mm Lock Washers
(4) 12mm Flat Washers
(2) 12mm Hex Nuts
Front
Fig 1
Front
Fig 2
(1) 12mm x 40mm Hex Bolts
(1) 12mm Lock Washers
(1) 12mm Flat Washers
Fig 3
Cut out the sections
illustrated to clear the
Mounting Brackets
Page 2 of 2 2/5/09 Rev 1(DP)
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