Yakima LockNLoad Flush Rail Mounting Kit User manual

28-13-355-Rev4 1/10
12
ITEM COMPONENT QTY ITEM COMPONENT QTY
1. Foot Extrusion x4 4. Claw Extrusion x4
2. Rubber Foot Pad x4 5. Rubber Clamp Pad x4
3. Rubber Foot Pad x4 6. Unpinned Grip Plate x4
MAX VEHICLE ROOF LOAD RATING: 100 KG
TOTAL LOAD EQUALS WEIGHT OF ROOF RACKS + ACCESSORIES + CARGO
• 4 mm Ball End Allen Key
• 5 mm Allen Key
• 13 mm Ring Spanner
• #2 Phillips Head Screwdriver
• Scissors
• Tape Measure
• Marking Pen (Optional)
• Torque Wrench (Optional)
TOOLS REQUIRED:
3
®LockNLoad Flush Rail Mounting Kit
FORD EVEREST 2015+
FLUSH RAIL HEAVY DUTY ROOF RACK SYSTEM
456
™
• Please read instructions carefully before installation.
• Check the contents of kit. Contact your YAKIMA dealer if any parts appear missing or damaged.
• Clean your roof thoroughly prior to itting the LockNLoad Flush Rail Heavy Duty Roof Rack System.
• Place these instructions in the vehicle’s glove box after installation is complete.
FIRST TIME INSTALLATION
KIT CONTENTS
LEG AND BAR COMPONENTS SOLD SEPARATELY

28-13-355-Rev4 2/10
INSTALLATION OF LNL PLATFORM TO FLUSH RAIL LEGS
CLAW ASSEMBLY
Insert an Unpinned Grip Plate into
each of the Clamp Claws from the
LockNLoad leg kit.
12
3Push padded Claw Extrusions
into the Clamp Claws. (When
assembled onto a vehicle these will
click into position).
4
REMOVE LEG COVERS
Using the keys supplied in
the LockNLoad Leg Kit (sold
separately), remove all Leg Covers.
FOOT ASSEMBLY
Slide Rubber Foot Pads onto each
Foot Extrusion.
Slide Rubber Clamp Pads over each of
the Claw Extrusions.
TABLE OF CONTENTS
INSTALLATION OF LNL PLATFORM TO FLUSH RAIL LEGS . . . . . . . . . . . . . . . . . 2
INSTALLATION OF LNL CROSSBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

28-13-355-Rev4 3/10
7INSTALL MOUNTING BLOCKS
Place Mounting Block from Platform kit on top of each Leg assembly, lining up the
rivnut holes on Mounting Block with holes on tabs of Leg Mounting Bracket.
Secure with M6 Capscrews and Washers from Platform kit, as shown. Tighten all
screws to 4 Nm with a 4 mm Ball End Allen Key or suitable Torque Wrench.
Note: The Mounting Block assembly will still have movement after securing which
is intended.
LEG LOCATION
Position front Legs onto the vehicle rail so that they are centred 55 mm from rear
of front door.
Recommended distance between centres of front and rear Legs is then 925 mm.
925 mm 55 mm
8
Push padded Foot Extrusions into
the rear cavity of LockNLoad Legs.
(When assembled onto a vehicle
these will click into position).
56LEG ASSEMBLY
Slide the Claw assembly into the
LockNLoad Leg, as shown.
Insert the M6 bolt and washer from
the Leg kit into the Leg and wind
(six revolutions) into the grip plate.

28-13-355-Rev4 4/10
ASSEMBLE LNL PLATFORM
Assemble Platform according to the LockNLoad Platform Assembly instructions
Steps 1 - 9 (Pages 4 - 7).
10
LIFT PLATFORM ONTO VEHICLE
With the help of an assistant, carefully lift assembled Platform up and onto
Mounting Blocks on vehicle roof. Centre Platform evenly on Legs so there is equal
overhang on both sides and ideally at front and rear.
Follow LockNLoad Platform Vehicle Mounting
instructions from Step 3 to complete install.
NOTE - Wind Delector, if used, is to be installed at the front of the vehicle (sold
separately).
11
SECURE LEGS
Secure Claw assemblies to the vehicle rail using a 5 mm Allen Key or Torque
Wrench. Torque to 4 Nm. Due to the geometry of the Everest lush rail, a small
gap may appear on the inboard face. This is acceptable and has been tested.
9

28-13-355-Rev4 5/10
TIGHTEN PIVOT ASSEMBLY
Use Spanner or Torque
Wrench to tighten M8 Nuts
on each Leg to 7 Nm.
12 FIT LEG COVERS
Fit Covers onto Legs and lock
using the keys supplied in the
LockNLoad Leg Kit.
13
14 LEG KEYS
Place one key on the vehicle key ring and put the other
away safely, or store with the spare vehicle key.
Write the key number (which is stamped on the key) in the box provided.
Replacement keys are available from Yakima stockists, visit www.yakima.com.au
or www.yakima.co.nz to ind your nearest store or contact us directly on 1800 143
548 (AU) or 0800 4776 722 (NZ).
Key Number:

28-13-355-Rev4 6/10
CLAW ASSEMBLY
Insert an Unpinned Grip Plate into
each of the Clamp Claws from the
LockNLoad leg kit.
12
3Push padded Claw Extrusions
into the Clamp Claws. (When
assembled onto a vehicle these will
click into position).
4
REMOVE LEG COVERS
Using the keys supplied in
the LockNLoad Leg Kit (sold
separately), remove all Leg Covers.
FOOT ASSEMBLY
Slide Rubber Foot Pads onto each
Foot Extrusion.
INSTALLATION OF LNL CROSSBARS
Slide Rubber Clamp Pads over each of the
Claw Extrusions.
Push padded Foot Extrusions into
the rear cavity of LockNLoad Legs.
(When assembled onto a vehicle
these will click into position).
56LEG ASSEMBLY
Slide the Claw assembly into the
LockNLoad Leg, as shown.
Insert the M6 bolt and washer from
the Leg kit into the Leg and wind
(six revolutions) into the grip plate.

28-13-355-Rev4 7/ 10
PIVOT ASSEMBLY
Assemble as shown. Loosely tighten
the M8 screw and ensure a suficient
gap remains between Nut Plate and
Leg to allow Bar to slide through in
next step.
89INSERT LEGS
Remove the End Caps from
LockNLoad Bars and slide
Leg assemblies into the
underside channel of each of
the Bars (sold separately).
7REMOVE PLATFORM
HARDWARE
Remove nut and washer
which have been loosely
pre-installed as shown.
Remove Coach Bolt and
Mounting Bracket.
BAR LOCATION
IMPORTANT: Before beginning Bar installation, identify where along the rail the
front and rear Bars should be itted.
Front Bar needs to be centred 55 mm from rear of front door.
Recommended distance between centres of front and rear Bars is then 925 mm.
55
m
m
925
m
m
10

28-13-355-Rev4 8/10
BAR PLACEMENT
Carefully place Bar assembly onto vehicle. Take care not to damage vehicle.
Slide Legs along Bar until foot clamp sits snug against vehicle rail.
Secure the Claw assembly to the vehicle rail using a 5 mm Allen Key or Torque
Wrench.
Torque to 4 Nm. Due to the geometry of the Everest lush rail, a small gap may
appear between clamp and rail. This is acceptable and has been tested.
Use a Tape Measure to ensure even Bar overhang on each side, re-adjust if
required.
Repeat process for remaining Bar.
11
=
=
CHECK BAR SLOT MEASUREMENTS
Using a Tape Measure, record Leg to underside slot
distance of each Bar in the table (right). Ensure
measurement is taken from the centre of the Legs
as shown. The ends of each bar should be the same
measurement respectively, if not, repeat Step 11.
BAR SLOT MEASUREMENTS
Front Bar (X) Rear Bar (Y)
______mm x2 ______mm x2
XX = X X
YY = Y Y
12
BAR SLOT COVERS
Cut Bar Slot Covers
as per measurements
recorded in the table
on Step 12 and push
into underside channel
of front and rear Bar
ends as shown.
NOTE - Bar Slot Covers to be
inserted with lat side visible.
14
SECURE LEGS TO BARS
Given that the pivot assembly allows for
degrees of freedom, check all plates are evenly
arranged and bars are in the desired position/
angle before tightening M8 Hex Bolt to 7 Nm.
13

28-13-355-Rev4 9/10
BAR SLOT COVERS (OUTSIDE LEG)
Measure the Bar channel outside of
the Legs and subtract 20 mm from
this measurement.
Using the remaining pieces of Slot
Cover from Step 14, cut to this
length and insert into the underside
channel of each Bar end as shown.
15
-20 mm
SECURE END CAPS TO BARS
Insert the End Caps as shown.
A Rubber Mallet can be used to
assist installation.
16 Secure using Plastite Screw. Tighten
using a #2 Phillips Head Screwdriver.
CHECK BAR LEGS ARE SECURE
Check all Bars/Legs are secure.
17 FIT LEG COVERS
Using the Keys and Covers
supplied in the LockNLoad Leg
Kit, it and lock all Leg Covers.
18

28-13-355-Rev4 10/10
19 BAR KEYS
Place one key on the vehicle key ring and put the other
away safely, or store with the spare vehicle key.
Write the key number (which is stamped on the key) in the box provided.
Replacement keys are available from Yakima stockists, visit www.yakima.com.
au or www.yakima.co.nz to ind your nearest store or contact us directly on
1800 143 548 (AU) or 0800 4776 722 (NZ).
Key Number:
www.yakima.com.au
www.yakima.co.nz
www.yakima.com
YAKIMA PRODUCTS, INC.
4101 Kruse Way
Lake Oswego, OR
97035-2541
USA
888 925 4621
YAKIMA AUSTRALIA PTY. LTD
17 Hinkler Court
Brendale, QLD 4500
Australia
1800 143 548