Yakima LOCKN'LOAD User manual

28-13-016-Rev1 1/10
LOCKN’LOAD TRACK MOUNTING KIT
TOYOTA HILUX DUAL CAB 2015+
2 BAR TRACK HEAVY DUTY ROOF RACK SYSTEM
• 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 fitting the LOCKN’LOAD Track Heavy Duty Roof Rack System.
• Place these instructions in the vehicle’s glove box after installation is complete.
FIRST TIME INSTALLATION
1
2
KIT CONTENTS
ITEM COMPONENT QTY ITEM COMPONENT QTY
1. Track Toyota Hilux Right Hand Side x1 7. Drill Bit x1
2. Track Toyota Hilux Left Hand Side x1 8. M6 Hex Screw x8
3. Track Nut Plate x4 9. End Cap Front Left & Rear Right x2
4. M6 Washer x8 10. End Cap Front Right & Rear Left x2
5. M6 Spring Washer x8 11. Rivet Gun Nozzle x1
6. Rivet x14
• Marking Pen
• Tape Measure
• Masking Tape
• Power or Cordless Drill
• Drill Bit Stop
• Vacuum Cleaner
• Mastic Silicone Sealant
• Fine Tooth Hacksaw
• Hammer
• Rubber Mallet (Optional)
• #2 Phillips Head Screwdriver
• Zinc Rich Cold Galvanising Coating
TOOLS REQUIRED:
MAX VEHICLE ROOF LOAD RATING: 100KG
TOTAL LOAD EQUALS WEIGHT OF ROOF RACKS + ACCESSORIES + CARGO
TM
®
• Flat Blade Screwdriver
• 10mm Open Ended Spanner
• 13mm Socket or Spanner
• Rivet Gun
• Scissors
• Centre Punch
• Automotive Degreaser
• Automotive Adhesive
3
84
10
9
7
6
5
LEG AND BAR COMPONENTS SOLD SEPARATELY 11

28-13-016-Rev1 2/10
MARK TRACK HOLES
With the help of an assistant, hold Track
down firmly in roof channel and mark all
holes using a Marking Pen. Remove Track.
3
2
TRACK INSTALLATION
TRACK ORIENTATION
The extrusion on side of Tracks faces
inside of vehicle as shown, with
rectangular cut outs at rear of vehicle.
1BEFORE BEGINNING INSTALLATION
Clean roof thoroughly and allow to dry before
beginning installation.
REMOVE ROOF CHANNEL TRIM
Gently lever the rubber roof channel trim with a
Flat Blade Screwdriver (wrap tape around end of
Screwdriver to prevent paint scratching). Then using
fingertips pull carefully upwards and unhook plastic
clips that are attached to the roof underneath each
end of the trim.
Store channel trim in a safe location for use in Step 13.
Place Tracks into roof
channel taking note of
Track orientation as shown
in the previous Step.
PLACE TRACKS INTO ROOF CHANNEL
TRACK MEASUREMENTS
Using a Tape Measure, measure 210mm
from the edge of the windscreen rubber
to the start of the Track as shown. Use
Masking Tape to mark measurement on
vehicle roof.
4
Vehicle Front
5
210mm
NOTE - image as viewed from rear of vehicle
210mm
Extrusion

28-13-016-Rev1 3/10
6CENTRE PUNCH HOLES
Using a Centre Punch
and Hammer, accurately
Centre Punch the
holes marked in the
previous Step.
7DRILL ROOF CHANNEL
Marked out holes can now be carefully drilled through using
the supplied Drill Bit and a Drill Stop which allows a
maximum drill depth of 6mm. Use a Drill Stop to ensure you
don’t drill through roof lining.
6mm
Drill Stop
8REMOVE SWARF
Avoid pushing swarf into
the newly drilled holes
by removing swarf from
roof channel with a
Vacuum Cleaner.
Vacuum swarf
9APPLY 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.
Stage 1
Apply liberally
in and around
holes
Stage 2
Apply liberally
in and around
holes
10 PLACE TRACKS BACK INTO ROOF CHANNEL
Accurately place Tracks over drilled holes in roof channel,
ensuring Track orientation is correct as shown.
1
2
34
567
!
Vehicle
Front
Warning!
Pay extra attention
when drilling 4th hole
as this is the location
of the side curtain
airbag gas cylinder
Extrusion

28-13-016-Rev1 4/10
Align Tracks and secure End Caps by inserting all Rivets
through Track into roof channel.
Using a Rivet Gun and the Rivet Nozzle provded, punch
each Rivet starting from the centre Rivet, then working
consecutively outwards
as shown.
1
2
35
4
6
7
To secure
End Caps,
insert Rivet
through End
Cap and Track
TRACK INSTALLATION
END CAP FITMENT
Assemble End Caps within Tracks as shown,
taking note of End Cap orientation.
Align End Cap and
slide into position
CUT ROOF CHANNEL TRIM TO SIZE AND REFIT
Thoroughly clean exposed roof channel at front
and rear of Tracks using an Automotive Degreaser
before refitting roof trim.
To conceal exposed roof channel at front and rear
of Tracks, cut to length the original roof trim
removed in Step 1. Measure out the required
length by positioning the trim along roof channel.
The front needs to be measured so the end of
trim sits under windscreen rubber. Use a pencil
to mark reference line. Remove trim from vehicle
and cut to length using a Hacksaw. Liberally
apply an Automotive Adhesive to roof channel
then refit trim pieces. Wipe off any excess
adhesive with a damp cloth and allow to dry.
Use a fine tooth
Hacksaw due to metal
inside rubber roof
trim. Alternatively tin
snips can be used
Rear Front
Liberally apply an
Automotive Adhesive
such as Sikaflex
11
12
13

28-13-016-Rev1 5/10
TRACK INSTALLATION COMPLETE
Check both Tracks are secured to the vehicle as per these installation instructions.
For assistance contact your local Yakima dealer.
PLEASE SEE STEPS 15-37 FOR BAR INSTALLATION
14

28-13-016-Rev1 6/10
BAR INSTALLATION
REMOVE LEG COVERS
Using the keys supplied in the
LOCKN’LOAD Leg Kit (sold separately),
remove all Leg Covers.
LEG ASSEMBLY
From the LOCKN’LOAD Leg Kit,
assemble 1 x M8 Spring Washer
and 1 x M8 Washer onto each
M8 Set Screw 16mm in the order
shown.
Loosely finger tighten Nut Plates to Legs as
shown using the screw assemblies from the
previous Step.
Ensure there is a sufficient gap between
the Nut Plates and Legs for the next Step.
From the
LOCKN’LOAD
Leg Kit, position
Nut Plates
over holes on
top of Legs.
INSERT LEGS
Slide Leg assemblies into the underside channel of
LOCKN’LOAD Bars (sold separately).
If Leg assemblies will not slide in,
loosen Screws to increase gap.
15 16
17 18
19

28-13-016-Rev1 7/10
CHECK BAR SLOT MEASUREMENTS
Using a Tape Measure record Leg to underside slot distance from the Bar used in the previous Step.
Ensure measurement is taken from the centre of the Legs as shown. Both ends should be the same
measurement, if not, repeat Step 20.
BAR PLACEMENT
Carefully place a Bar assembly over Track. Take care not to damage vehicle. Slide Legs along Bar
until both legs are securely positioned within Track. Use a Tape Measure to ensure even Bar
overhang on each side, re-adjust if required. Finger tighten one of the Leg Screws on
each Leg so they are secure, then carefully remove Bar from vehicle.
=
=
==
BAR SLOT COVERS
Cut Bar Slot Covers into four pieces according to the measurement taken in Step 21. Insert
into underside channel of front and rear Bar ends as shown.
NOTE - Bar Slot Covers to be
inserted with flat side visible
=
=
Remove Legs from Bar once equal measurement is
obtained. Finger loosen Screws, keeping Nut Plate
and Screw assemblies in place as shown.
20
21
22

28-13-016-Rev1 8/10
INSERT LEGS
Slide Leg assemblies into the underside channel of
LOCKN’LOAD Bars. Slide in until Leg reaches Slot Cover.
Do not compress slot cover.
Connect all End Cap Halves together.
END CAP ASSEMBLY
From the LOCKN’LOAD Leg
Kit, insert Bottle Openers and
Pins into the End Cap Halves.
SECURE LEGS TO BARS
Tighten all M8 Set Screws
to 7Nm using a 13mm
Socket Wrench.
BAR SLOT COVERS (OUTSIDE LEG)
Measure the Bar channel outside of the Legs and
subtract 20mm from this measurement. Using the
remaining pieces of Slot Cover from Step 22, cut to
this length and insert into the underside channel of
each Bar end as shown.
24 25
26
27
-20mm
23

28-13-016-Rev1 9/10
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 LOCKN’LOAD Leg Kit).
Tighten using a #2 Phillips Head
Screwdriver.
15
SECURE BARS TO TRACKS
From the LOCKN’LOAD Track Kit, assemble
1 x M6 Spring Washer and 1 x M6 Washer
onto each M6 Hex Screw as shown. Insert
through the outer holes on Legs into Nut
Plate as shown. Finger tighten Screws.
Position front and rear Bars along
Tracks as required, ensuring there
is a minimum distance of 700mm
between each Bar. Measure from
the centre of each Leg as shown.
≥ 700mm
28 29
30
32 33
BAR FITMENT
Slide Nut Plates within Track into position for front and
rear 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.
this
31
INSERT NUT PLATES
Run all M6 Hex
Screws through
Nut Plates to
remove burs.
Insert two (2) Nut Plates into
each Track as shown.
Nut Plate
33

28-13-016-Rev1 10/10
CHECK BAR LEGS ARE SECURE
Check all Bar Legs are secure.
FIT LEG COVERS
Using the keys and Covers
supplied in the LOCKN’LOAD Leg
Kit, fit and lock all Leg Covers.
Tighten all M6 Hex Screws to 5Nm using
a 10mm Open Ended Spanner
Do not over tighten.
34 35
36 37 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
find your nearest store or contact us directly
on 1800 143 548 (AU) or 0800 4776 722 (NZ).
Key Number: