Kaon KS0640 User manual

Scan the QR code to watch the video installation guide,
or for further information contact KAON on 07 3180 1470 or [email protected]
FITTING INSTRUCTIONS FOR
Standalone Rear Roof Shelf
SKU COMPATIBILITY
KS0640 Toyota Prado 150
30 minutes / Half a beer
Time
Included contents
QTY COMPONENT QTY COMPONENT
1 Rear Roof Shelf 4 M5 x 12 Flanged Hex Bolts
1 Rear Fence 4 M5 Flanged Nuts
2 Handle Brackets 4 M6 x 16 Flanged Bolts
4 M6 Flanged Nuts

2
With your setup order sorted, let’s get to the good part: installing.
YES YES
YES YES
Assemble the Molle Panel
as per it’s instructions.
Now’s the time to mount
any additional accessories
to the Molle as well.
Follow the Shelf fitting
guide, and if relevant, the
Side Molle option for your
setup. Complete the
Shelf & Molle install.
Are you installing a
Side Molle Panel?
It all works together.
All our storage products work together, but there is a certain order to installing.
Let’s work out the best order for your setup, shall we?
Are you installing other
KAON Storage Products?
Are you installing other
KAON Storage Products?
With the foundation in
place, it’s time to mount
any other accessories,
such as a Cargo Divider,
Travel Buddy, etc. Have
fun making it your own.
Complete the Molle Panel
as per it’s instructions. That’s it, you’re done! That’s it, you’re done!
NO NO NO
NO NO
Are you installing a
Standalone Shelf?
Are you installing a
Light Cargo Barrier?
YES
Are you installing other
KAON Storage Products?
The last piece of the
puzzle, complete your
install by following the
Light Cargo Barrier
fitting guide.
YES

Let’s get to work.
4 5
Assembling the Shelf
3. Attach the rear fence to the shelf
using M5 nuts and bolts.
4. Tighten to secure.
2
4
Preparing the Vehicle
1. Pry open the plastic covers on the
rear grab handles with a small
flatblade screwdriver or trim tool.
2. Use a 10mm socket to remove the
rear handles. Set aside.
1
2
2

6 7
Installing the Shelf
13. With the brackets up, it’s time to
install the shelf itself. Whilst this
can be done on your own, you may
find it easier to ask a mate for help.
14. Position the shelf and use the M6
bolts and nuts to install the shelf
to the bracket. There are a couple
of positions for adjustment in your
shelf positioning.
15. With the shelf position confirmed,
tighten all the bolts.
16. That’s it! Your new shelf is able to
hold a recommended maximum
load of 10kg. It also has some handy
hooks to hang bags, and twin bottle
openers on each side.
If you’re adding a Light Cargo Barrier:
17. Follow steps 10-15 in the Light
Cargo Barrier instructions to
assemble and install.
14
15
17
Installing the Brackets
To install the Standalone Shelf
with or without a Light Cargo Barrier:
5. Attach the handle brackets using
M6 flanged bolts, and reattach the
handles. Ensure the nutsert is at the
top, towards the front of the vehicle,
as pictured.
6. Tighten to secure.
To install with the Side Molle Panels:
7. Ensure you have the correct molle
panel for each side, with the ‘K’
positioned at the back of the vehicle.
8. Sandwich the Standalone Shelf
handle brackets over the Molle
Panel top mounts. Ensure the
nutsert is at the top, towards the
front of the vehicle, as pictured.
9. Secure the bolts. Youcan opt
to retain the factory bolts and
reinstall the grab handle over the
top, or, the molle panel includes
washers which can be used instead
of the factory hardware.
10. Install the Side Molle Panel lower
mount bracket using it’s included
M6x50 bolt.
11. Check the spacing and position of
the Side Molle Panel, and tighten all
bots to secure.
12. Tighten to secure.
5
8
8

Scan the QR code to watch the video installation guide,
or for further information contact KAON on 07 3180 1470 or [email protected]
FITTING INSTRUCTIONS FOR
Light Cargo Barrier
SKU VARIANT COMPATIBILITY
KS0606 7-Seater Toyota Prado 150, Lexus GX 460
Included contents
QTY COMPONENT QTY COMPONENT
1 Light Cargo Barrier 2 M10 Wave Washer
2 Head Rest Bracket 2 M6 X 18 X 1.6 DIN Flat Washer
2 Handle Bracket (LHS & RHS) 2 M10 x 20 Button Head Socket Screw
2 Barrier Bracket (LHS & RHS) 2 M10 x 30 x 2.5 DIN Flat Washer
2 M10 x 20 Black Plastic Knob 2 M6 x 16 Flanged Hex Bolt G8.8
30 minutes / Half a beer
Time

2
With your setup order sorted, let’s get to the good part: installing.
YES YES
YES YES
Assemble the Molle Panel
as per it’s instructions.
Now’s the time to mount
any additional accessories
to the Molle as well.
Follow the Shelf fitting
guide, and if relevant, the
Side Molle option for your
setup. Complete the
Shelf & Molle install.
Are you installing a
Side Molle Panel?
It all works together.
All our storage products work together, but there is a certain order to installing.
Let’s work out the best order for your setup, shall we?
Are you installing other
KAON Storage Products?
Are you installing other
KAON Storage Products?
With the foundation in
place, it’s time to mount
any other accessories,
such as a Cargo Divider,
Travel Buddy, etc. Have
fun making it your own.
Complete the Molle Panel
as per it’s instructions. That’s it, you’re done! That’s it, you’re done!
NO NO NO
NO NO
Are you installing a
Standalone Shelf?
Are you installing a
Light Cargo Barrier?
YES
Are you installing other
KAON Storage Products?
The last piece of the
puzzle, complete your
install by following the
Light Cargo Barrier
fitting guide.
YES

4 5
Let’s get to work.
Preparing the Vehicle
1. Pry open the plastic covers on the
rear grab handles with a small
flatblade screwdriver or trim tool.
2. Use a 10mm socket to remove the
rear handles. Set aside.
Installing the Brackets
To install the Light Cargo Barrier:
3. Install the handle brackets to the
roof mounts, as pictured. Ensuring
the nutsert is towards the front of
the vehicle, tighten tosecure.
To install with the Standalone Shelf
4. Follow the instructions provided
with the Standalone Shelf, then
skip to step 10 below.
Please note pre-2023 Standalone Shelves
(KS0265) require the shelf bracket to be
layered. Refer to our website for more details.
To install with the Side Molle Panels:
5. Ensure you have the correct molle
panel for each side, with the ‘K’
positioned at the back of the vehicle.
6. Sandwich the barrier handle
brackets over the Molle Panel
top mounts. Ensuring the handle
bracket nutsert is towards the front
of the vehicle.
7. Secure the top using the M6 bolts
and washers.
8. Install the Side Molle Panel lower
mount bracket using it’s included
M6x50 bolt.
9. Check the spacing and position of
the Side Molle Panel, and tighten all
bots to secure.
1
2
2
3
5
8

6 7
112
14
15
Assembling the Barrier
10. Attach the barrier brackets to
the barrier using the supplied
bolts, ensuring that the barrier
brackets are attached in the correct
orientation.
Installing the Barrier
11. Remove the head rests and
slideonthe head rest brackets.
Re-installthe head rests with
brackets in place.
12. Position the main barrier against
the head rests. The flanged edge
on the barrier should be directed
forwards, and the warning stickers
should be visible from the rear of
the vehicle.
13. Loosely secure it to the head rest
brackets using the M10 domed head
bolts and M10 washer.
14. Attach the barrier bracket tothe
handle bracket nutsert using
the M10 knob and anti-rattle
wavewasher. You can adjust the
position of the barrier byselecting
the most suitable hole in the
barrierbracket.
15. Once the barrier is in the desired
position, tighten all bolts and
knobssecurely. That’s it, you’re
done! The barrier can be quickly
removed by removing the plastic
knobs and lifting out the head rests.

8
Disclaimer: The products sold by KAON should not be modified, and are for use only on the vehicles specifically stated. KAON will not be
liable for any damages arising out of the use or misuse of it’s products. It is the customers responsibility to ensure the products are safely
and properly used and installed. KAON consistently seeks to improve it’s products and reserves the right to make changes to any product.
Local Knowledge & Assistance
We know half the fun of building your dream 4x4 is getting your hands
dirty. But we also know that sometimes, things don’t go to plan. If in the
pursuit to build the ultimate setup you find yourself off-track, we’re here
tohelp you get unstuck.
For further information call 07 3180 1470 or email [email protected]om.au
Bolt Torque
DIAMETER (mm) 5mm 6mm 8mm 10mm 12mm
NEWTON-METRES (Nm) 5 Nm 9 Nm 22 Nm 44 Nm 77 Nm
This barrier has not been tested to Australian Standards,
and is intended as a petbarrier or for use when off-road.
NOTICE