Yakima LockNLoad Series User manual

28-13-011-Rev4 1/17
1
9
ITEM COMPONENT QTY ITEM COMPONENT QTY
1. Track Colorado/D-Max Right Hand Side x1 8. M6 Hex Screw x8
2. Track Colorado/D-Max Left Hand Side x1 9. Track End Cap x4
3. Track Nut Plate x4 10. M8 Button Head Screw x8
4. M6 Washer x8 11. M8 Spring Washer x8
5. M6 Spring Washer x8 12. M8 Washer x8
6. Rivet x8 13. 5mm Allen Key x1
7. 4.9mm Drill Bit x1
HOLDEN COLORADO / ISUZU D-MAX DUAL CAB 2012+
TRACK MOUNT HEAVY DUTY ROOF RACK SYSTEM
• Marking Pen
• Tape Measure
• Masking Tape
• Scissors
• 3 mm Drill Bit
• 7 mm Drill Bit
• Drill Bit Stop
• Rivet Gun
• Tin Snips
• Flat Blade Screwdriver
• #2 Phillips Head Screwdriver
• Zinc Rich Cold Galvanising Coating
MAX VEHICLE ROOF LOAD RATING: 100KG
TOTAL LOAD EQUALS WEIGHT OF ROOF RACKS + ACCESSORIES + CARGO
®
• Mastic Silicone Sealant
• Vacuum Cleaner
• 10mm Open Ended Spanner
• 13mm Socket or Spanner
• Metal File
• Die Grinder (D-Max SX only)
• Rubber Mallet (Optional)
• Power or Cordless Drill
3
8
4
7
6
5
2
10
11
12
13
LockNLoad Track Mounting Kit
™
• 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 Track Heavy Duty Roof Rack System.
• Place these instructions in the vehicle’s glove box after installation is complete.
FIRST TIME INSTALLATION
TOOLS REQUIRED:
KIT CONTENTS
LEG AND BAR COMPONENTS SOLD SEPARATELY

28-13-011-Rev4 2/17
TRACK INSTALLATION
TRACK ORIENTATION
NOTE - image as viewed from rear of vehicle
TRACK SET-UP
It is recommended to completely install one track at a time.
M8 Button Head
Screws
Rivets
Isuzu D-Max SX
Vehicle Front
Holden Colorado / Isuzu D-Max LS, LS-U, LS-M
M8 Button Head
Screws
Rivets
NOTE - image as
viewed from above
Rectangular cut out at rear of vehicle Vehicle Front
The foam tape
on side of Tracks
faces outside
of vehicle as
shown, with
rectangular cut
outs at rear
of vehicle.
Foam Tape Foam Tape
BEFORE BEGINNING
INSTALLATION
Clean roof thoroughly
and allow to dry before
beginning installation.
12
3
NOTE - image as
viewed from above
Rectangular cut out at rear of vehicle

28-13-011-Rev4 3/17
MEASURE ROOF TRIM
Using a Tape Measure, measure 1420 mm from the edge of the windscreen rubber
(not glass edge) back along rubber roof channel trim. Ensure to measure from the
centre of roof trim as shown. Use a pencil to mark measurement at 1420 mm and
another at 230 mm. Vehicle Front
NOTE - image as viewed from above
Rubber roof
channel trim
Windscreen rubber
230 mm
1190 mm
DRILL ROOF TRIM
The measurements can now be carefully drilled through using a 3 mm Drill Bit (not
supplied) by drilling three holes through the trim at the two marked locations. The
trim has a stainless steel section inside. Do not drill into the roof.
5
Mark measurement
on trim with a pencil Mark measurement
on trim with a pencil
230 mm
1190 mm
Vehicle Front
!
Warning!
Use care when breaking through the
roof trim to not drill into the roof.
CUT ROOF TRIM
To protect paint work, place Masking Tape over middle of roof as
shown. Gently lever up the middle of rubber roof channel trim with a
Flat Blade Screwdriver (wrap tape around end of Screwdriver to prevent
paint scratching). Use Tin Snips to cut through middle of trim.
6
Masking tape
needs to also
cover the inside
ridge of channel
as shown.
4
!

28-13-011-Rev4 4/17
3
4 12
BREAK ROOF TRIM
Using your thumb to support trim at drilled holes, bend the cut trim sections
back and forth to break at drilled holes. Some force may be required to snap
the stainless steel section in trim.
Neaten edges where trim has broken as much as possible.
Remove all Tape from vehicle roof.
7
REVEAL MOUNTING POINTS
With the trim pieces removed, the M8 mounting points can now
be accessed. The mounting points are covered with paint and
tape. Use a sharp tool to remove paint and peel away tape covering
holes to reveal screw thread. If the roof panel overlaps the hole
and impedes on accessing the thread, carefully ile the roof panel
to allow clearance for inserting the M8 Button Head Screws.
8
NOTE - Isuzu D-Max SX Models do not feature a
third (#3) mounting point. Proceed to Page 10
for supplement D-Max SX itting instructions.
File overlapping panel if shape of hole won’t
allow clearance for inserting the
M8 Button Head Screws.

28-13-011-Rev4 5/17
ALIGN AND SECURE TRACK
Place Track into roof channel, ensuring Track orientation is correct as shown.
Align Track and eliminate movement within the roof channel during spot drilling by
inserting M8 Button Head Screws into each of the mounting holes through track.
Secure using the supplied Allen Key.
Isuzu D-Max SX models secured using holes 1, 2 and 4.
9
Vehicle Front
Foam Tape Foam Tape
SPOT DRILL RIVET HOLES
Using the supplied 4.9 mm Drill Bit, drill
each of the applicable rivet holes as
shown below. Start from the rear of the
vehicle working consecutively frontward.
Ensure the Track does not move during
this process by maintaining downward
pressure on the Track while spot drilling
holes. Use the help of an assistant if
required. Once complete, remove Track
taking care not to scratch vehicle.
10
Vehicle Front
Holden Colorado / Isuzu D-Max LS, LS-U, LS-M
Isuzu D-Max SX
Vehicle Front
NOTE - image as
viewed from above
Rivet holes
Drill
frontward
Rivet holes
NOTE - image as
viewed from above

28-13-011-Rev4 6/17
DRILL ROOF CHANNEL
All rivet holes can now be carefully drilled through. To avoid drilling into roof lining
a drill stop must be used. The roof skin is approx. 2-3 mm thick.
Ensure that a drilling angle perpendicular to the roof angle is maintained.
11
Drill
Stop
REMOVE SWARF
Avoid pushing
swarf into the
newly drilled
holes by removing
swarf from roof
channel with a
Vacuum Cleaner.
Vacuum swarf
APPLY PROTECTIVE
SEALANTS
Stage 1
Liberally apply a Zinc Rich
Cold Galvanising Solution
to the inside surface and
surrounds of each drilled
hole. Allow solution to
become touch dry before
proceeding with Stage 2
(approx. 10 min depending
on product used).
Stage 2
Liberally apply a Mastic
Silicone Sealant to
the inside surface and
surrounds of each hole,
including the threaded
M8 mounting holes.
Stage 1
Apply liberally in
and around holes
Stage 2
Apply liberally in
and around holes
12 13

28-13-011-Rev4 7/17
PLACE TRACK
BACK INTO
ROOF CHANNEL
Accurately place
Tracks over
drilled holes in
roof channel,
ensuring Track
orientation is
correct as shown.
Foam Tape Foam Tape
14
INSERT NUT PLATES
Run all of the M6 Hex Screws
through the Nut Plates as shown.
This will aid installation in Step 36
END CAP FITMENT
Assemble End Caps within Tracks as shown, taking note of End Cap orientation.
Align End
Cap and slide
into position
Slide Nut Plates into each
Track end.
15
16

28-13-011-Rev4 8/17
INSTALL M8 SCREWS AND SECURE END CAPS
Assemble 1 x M8 Spring Washer and 1 x M8 Washer onto each M8 Button Head
Screw in the order shown and insert into the M8 Screw holes through Track.
Tighten to 7 Nm.
17
Isuzu D-Max SX
Vehicle Front
Holden Colorado / Isuzu D-Max LS, LS-U, LS-M
Vehicle Front
To secure End Caps, insert M8 Screw assembly
through End Cap and Track. Tighten to 7 Nm.
TRACK INSTALLATION
Align Track and insert all Rivets in their respective holes through Track into roof
channel.
Using a Rivet Gun, punch each Rivet starting from the centre
Rivet, then follow the numerical riveting order as shown.
18
3
4
4
4
4
1
2
Isuzu D-Max SX
models require
a fourth rivet
as shown
To secure End Caps, insert M8 Screw assembly
through End Cap and Track. Tighten to 7 Nm.
Vehicle Front

28-13-011-Rev4 9/17
TRACK INSTALLATION COMPLETE
Check both Tracks are secured to the vehicle as per these installation instructions.
For assistance contact your local Yakima dealer.
19
IF INSTALLING LockNLoad ROOF RACKS, CONTINUE
ON STEP 20
IF INSTALLING LockNLoad PLATFORM, NOW SWITCH
TO YOUR PLATFORM INSTRUCTIONS
!

28-13-011-Rev4 10/17
ISUZU D-MAX SX SUPPLEMENT STEPS
SPOT DRILL MOUNTING POINTS
Place Track into roof channel, ensuring Track orientation is correct as shown.
Using a 3 mm Drill Bit (not supplied), spot drill the centre of the irst, second
and fourth M8 mounting points in the Track as shown. Ensure the Track
does not move during this process by maintaining downward pressure on
the Track while spot drilling holes. Use the help of an assistant if required.
Once complete, remove Track taking care not to scratch vehicle.
1A
4
1
2
NOTE - Ensure to use the
holes numbered and not
the smaller rivet holes
Foam Tape Foam Tape
DRILL ROOF CHANNEL
The spot drilled Mounting
Points can now be opened
out using a 7 mm Drill
Bit (not supplied).
1B
4
1
2
Vehicle Front
Vehicle Front
DIE GRIND HOLES
Die Grind the opened out
holes from the previous
steps. This will expose the
M8 mounting points below.
2
4
1
2
Vehicle Front
REMOVE SWARF
Avoid pushing swarf into the
newly drilled holes by removing
swarf from roof channel
with a Vacuum Cleaner.
Vacuum swarf
APPLY GALVANISING
SOLUTION
Apply liberally in
and around holes
Liberally apply a Zinc Rich
Cold Galvanising Solution
to the inside surface and
surrounds of each hole.
Allow solution to become
touch dry (approx. 10 min
depending on product used).
34
GO BACK TO PAGE 5 AND
FOLLOW STEPS 9 - 40 TO
COMPLETE INSTALLATION
5

28-13-011-Rev4 11/17
BAR INSTALLATION
REMOVE LEG COVERS
Using the keys supplied
in the LockNLoad Leg
Kit (sold separately),
remove all Leg Covers.
INSERT LEGS
Slide the pre-assembled Leg
assemblies into the underside
channel of LockNLoad Bars.
If Leg assemblies
will not slide in,
loosen Screws to
increase gap.
From the LockNLoad Bar
Kit (sold separately), remove
Plastite Screw from each Bar
end using a #2 Phillips Head
Screwdriver and pull out End
Caps from Bars.
Keep all parts aside for
later installation.
REMOVE END CAPS FROM BARS
20
BAR LOCATION
IMPORTANT: Before beginning Bar installation, identify where along the Track
you want the Front and Rear Bars itted.
We recommend a minimum of 700 mm between Bars.
≥ 700 mm
21 22
23

28-13-011-Rev4 12/17
24 BAR PLACEMENT
Carefully place a Bar assembly over Nut Plates, ensuring spacing is correct as
shown in the previous Step. Take care not to damage vehicle. Position Legs
along Bar until both legs are securely positioned on Nut Plates within Track.
SECURE BAR
ASSEMBLY TO TRACKS
From the LockNLoad
Track Kit, insert 1 x M6
Hex Screw through
the two outer holes on
Legs into Nut Plate as
shown.
Loosely secure Screws
using a 5 mm ball end
Allen Key.
25
=
ADJUST BAR OVER HANG
Use a Tape Measure to ensure even Bar overhang on each side, re-adjust if
required by sliding bar along legs.
26
=

28-13-011-Rev4 13/17
CHECK BAR SLOT MEASUREMENTS
Place Bars on lat surface with legs facing upwards, as
shown. Take appropriate measures to avoid scratching
the product and surface.
Identify slot on each Bar end. 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.
XX
YY
X = X
Y = Y
29
BAR SLOT
MEASUREMENTS
Bar 1 (X)
______mm x2
Bar 2 (Y)
______mm x2
The ends of each bar should be the same
measurement respectively, if not, loosen M8
Set Screws and repeat Steps 24 - 29.
SECURE LEGS TO BARS
Tighten all M8 Set
Screws to 9 Nm using
a 13 mm Spanner.
27 REPEAT AND REMOVE
Repeat Steps 24 - 27 for
remaining bar assembly.
Carefully remove all Bar and
Leg assemblies from vehicle.
28

28-13-011-Rev4 14/17
SECURE END CAPS TO BARS
Insert the End Caps as shown. A Rubber
Mallet can be used to assist installation.
Secure using Plastite Screw
(from LockNLoad Bar Kit).
Tighten using a #2 Phillips
Head Screwdriver.
32 33
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 the previous
Step, cut to this length and
press into the underside channel
of each Bar end as shown.
31
-20 mm
BAR SLOT COVERS (INSIDE LEG)
From the LockNLoad Bar Kit, cut Bar Slot
Covers as per measurements recorded
in the previous Step and press into the
underside channel of Bar ends as shown.
NOTE - Bar Slot Covers to be
inserted with lat side visible
30

28-13-011-Rev4 15/17
Position front and rear Bars along Tracks as required, ensuring there is a minimum
distance of 700 mm between each Bar.
Measure from the centre of each Leg as shown.
35
M6 HEX SCREW ASSEMBLY
From the LockNLoad Track
Kit, assemble 1 x M6 Spring
Washer and 1 x M6 Washer
onto each M6 Hex Screw.
Insert through the outer
holes on Legs into Nut
Plates as shown.
36
BAR FITMENT
Slide Nut Plates in Track into position for Bar placement (it doesn’t have
to be exact). Place Bar assembly onto Tracks, carefully locating the four
central raised notches on base of Legs into the cut outs on Nut Plates as
shown. Take care not to damage vehicle. Repeat for remaining Bar.
34
≥ 700 mm

28-13-011-Rev4 16/17
4039
Key Number:
FIT LEG COVERS
Using the keys and
Covers supplied
in the LockNLoad
Leg Kit, it and lock
all Leg Covers.
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).
CHECK BAR LEGS ARE SECURE
Check all Bar Legs are secure.
SECURE BARS TO TRACKS
Tighten all M6 Hex Screws to 5
Nm using a 10 mm Open Ended
Spanner. Do not over tighten.
37 38

28-13-011-Rev4 17/17
www.yakima.com.au
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