Yakima LOCKN'LOAD User manual

28-13-021-Rev1 1/15
LOCKN’LOAD TRACK MOUNTING KIT
LAND ROVER DISCOVERY 3 & 4
HEAVY DUTY ROOF RACK TRACK 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
KIT CONTENTS - FRONT TRACKS (see pages 2-5)
ITEM COMPONENT QTY ITEM COMPONENT QTY
1. Track Front Land Rover Disco 3&4 x2 6. M6 Button Head Capscrew x2
2. Track Nut Plate x2 7. Rivet 13.5mm x4
3. M6 Washer x6 8. End Cap Front Left & Rear Right x2
4. M6 Spring Washer x6 9. End Cap Front Right & Rear Left x2
5. M6 Hex Screw x4 10.
MAX VEHICLE ROOF LOAD RATING*:
FRONT: 35KG REAR: 75KG
TOTAL LOAD EQUALS WEIGHT OF ROOF RACKS + ACCESSORIES + CARGO *Manufacturer’s Rated Maximum
TM
®
• Marking Pen/Pencil
• Power or Cordless Drill
• #2 Phillips Head Screwdriver
• Vacuum Cleaner
• Mastic Silicone Sealant
• Fine Tooth Hacksaw
• Rivet Gun
• Rubber Mallet (Optional)
• Drill Stop
• Tape Measure
• Zinc Rich Cold Galvanising Coating
TOOLS REQUIRED:
• Flat Blade Screwdriver
• 10mm Open Ended Spanner
• 13mm Socket or Spanner
• 4mm Allen Key
• Torque Wrench (Optional)
• Double Sided Tape
• Centre Punch
• Hammer
• Thread Locking Compound
LEG AND BAR COMPONENTS SOLD SEPARATELY
1
8
9
8
9
3
2
4
6
5
7
FRONT & REAR TRACK KITS SOLD SEPARATELY

28-13-021-Rev1 2/15
KIT CONTENTS - REAR TRACKS (see pages 6-11)
ITEM COMPONENT QTY ITEM COMPONENT QTY
1. Track Rear Land Rover Disco 3&4 RHS x1 8. Rivet 22mm x2
2. Track Rear Land Rover Disco 3&4 LHS x1 9. End Cap Front Left & Rear Right x2
3. Track Nut Plate x4 10. End Cap Front Right & Rear Left x2
4. M6 Washer x14 11. Mounting Boss x2
5. M6 Spring Washer x12 12. Button Head Capscrew with Loctite x2
6. M6 Hex Screw x8 13. Drill Bit 4.9mm x1
7. M6 Button Head Capscrew x4
BEFORE BEGINNING INSTALLATION
Clean roof thoroughly and allow to
dry before beginning installation.
It is recommended to install
one Track at a time.
4
1
2
3
5
6
7
8
9
9
10
10
11
12
13
LEG AND BAR COMPONENTS SOLD SEPARATELY FRONT & REAR TRACK KITS SOLD SEPARATELY

28-13-021-Rev1 3/15
TRACK INSTALLATION - FRONT
1REMOVE ROOF
CHANNEL TRIM
Lift rubber roof trim up and
outwards at rear of vehicle
using fingers.
Gently twist trim to unhook
plastic clips. Do not use
excessive force as the clips
could break.
Store roof trim aside for use
in Step 3.
2REMOVE PLUGS
Using a Flat Blade
Screwdriver (wrap tape
around end of Screwdriver
to prevent paint scratching
if you should slip), lever out
the front plastic plug in roof
channel to expose nutsert.
Do not remove
the nutsert.
3
CUT ROOF CHANNEL TRIM
Remove trim from vehicle and cut the
two outer marked lines using a Fine Tooth
Hacksaw.
4
100mm 100mm
MEASURE ROOF CHANNEL TRIM
Lay roof trim removed in Step 1 next to roof channel,
aligning the front of trim with windscreen edge. Using
a pencil, mark the trim in line with the center of nutsert.
Measure 100mm either side of nutsert centre line and
mark as shown.

28-13-021-Rev1 4/15
ASSEMBLE AND INSERT
SCREWS
Assemble 1 x Spring
Washer and 1 x Washer
onto each M6 Button
Head Capscrew.
Insert Screw
assemblies into
the centre hole
on Tracks as
shown.
8
RIVET END CAPS TO TRACK
Insert the supplied Rivets through the
two end holes on Track. Use a Rivet
Gun to secure End Caps to Track.
7
CONNECT END CAPS
Insert End Caps into Track ends.
6
REFIT ROOF TRIM
Return the two pieces of
trim cut in the previous
step back into roof
channel as shown.
Ensure trim is
hooked back onto
the roof channel via
the plastic clips.
5
TRACK ORIENTATION
The longest side flange faces outside of
vehicle as shown.
9
Spring Washer
Washer

28-13-021-Rev1 5/15
FRONT TRACK INSTALLATION COMPLETE
Check both Tracks are secured to the vehicle as per these installation instructions.
For assistance contact your local Yakima dealer.
11
PLEASE SEE NEXT PAGE FOR REAR TRACK INSTALLATION
PLEASE SEE PAGES 11-15 FOR BAR INSTALLATION
TRACK INSTALLATION
Place Track into roof
channel, ensuring
Track orientation is
correct as shown in the
previous Step. Locate
the Capscrew in centre
of Track into the nutsert
in roof channel. Tighten
Capscrew to 4Nm using
a 4mm Allen Key or a
suitable Torque Wrench.
10

28-13-021-Rev1 6/15
TRACK INSTALLATION - REAR
CUT ROOF CHANNEL TRIM
Away from vehicle, cut trim along marked
lines recorded in Step 1 using a Fine Tooth
Hacksaw.
Store aside one of the white plastic
clips from middle cut section of
trim for later use in Step 13.
3
BEFORE BEGINNING INSTALLATION
Clean roof thoroughly and allow to dry before beginning installation.
It is recommended to install one Track at a time.
1MEASURE REAR ROOF
CHANNEL TRIM
Using a Tape Measure,
measure 1530mm forward
from the edge of the rear
roof channel trim as shown.
Record measurement
lines on trim with a
pencil at 1530mm and
another at 100mm.
1530mm
100mm
Vehicle Front
100mm 1530mm
REMOVE ROOF CHANNEL TRIM
If rubber roof trim was not previously removed for the front Track installation, remove now.
Lift rubber roof trim up and outwards at rear of vehicle using fingers.
Gently twist trim to unhook plastic clips. Do not use excessive force as the clips could break.
2
1530mm
Middle cut section
100mm
Retain
Retain

28-13-021-Rev1 7/15
PLACE TRACK
Taking note of the Track orientation
shown in the previous Step,
fasten the Track to nutsert in
roof channel via the front track
hole using 1 x M6 Button Head
Capscrew. Finger tighten screw.
6
TRACK ORIENTATION
The longest side flange faces outside of
vehicle as shown.
5
REMOVE PLUGS
Using a Flat Blade Screwdriver (wrap tape around end of Screwdriver to prevent paint scratching
if you should slip), lever out the 3 plastic plugs in each side of roof channel to expose nutserts.
Do not remove the nutserts.
4
CENTRE PUNCH REAR
RIVET POSITION
With the Track in place,
use a Centre Punch
to gently mark the
rear rivet position.
Remove Track.
7
Vehicle Front
1
2
3
1

28-13-021-Rev1 8/15
DRILL ROOF
Using supplied 4.9mm Drill Bit and a Drill Stop, carefully
drill through the roof channel at the marked location.
Only drill enough to just break through roof skin.
Ensure a drilling angle perpendicular to the roof surface
is maintained throughout.
9REMOVE SWARF
Avoid scratching and
pushing swarf into
the newly drilled hole
by removing swarf
from roof channel with
a Vacuum Cleaner.
Vacuum swarf
10
Stage 1
Apply liberally in
and around hole.
Allow to dry.
Stage 2
Apply liberally in
and around hole.
11
REVEAL REAR RIVET
FIXING POINT
The rear rivet fixing
point is covered with
sealant. Use a sharp
tool to scrape away
enough seal so that
Mounting Boss can
seat correctly.
8
POSITION
MOUNTING BOSS
While Mastic Silicone
Sealant is still wet,
position Mounting
Boss on top of
seal over drilled
hole as shown.
12
APPLY PROTECTIVE
SEALANTS
Stage 1
Liberally apply a Zinc
Rich Cold Galvanising
Solution to the inside
surface and surrounds
of the 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 hole.

28-13-021-Rev1 9/15
CONNECT END CAPS
Insert End Caps into both
Track ends.
15
ALIGN AND SECURE TRACK
IN ROOF CHANNEL
Align Track in roof channel by
inserting the two remaining M6
Washer and Button Head Capscrew
assemblies into the middle hole and
then the rear hole as shown.
Tighten all three Capscrews to 4Nm
using a 4mm Allen Key or a suitable
Torque Wrench.
17
Apply Double
Sided Tape to the
underside of small
rear trim piece cut
in Step 3, and to the
fin of roof channel
as pictured.
Attach one of the
white plastic roof
trim clips removed
in Step 3 to the
Doubled Sided
Tape on underside
of trim as shown.
13 REFIT ROOF TRIM
Return the two pieces of trim cut in
Step 3 back into roof channel as shown.
Ensure trim is hooked back onto the
roof channel via the plastic clips.
14
ATTACH PLASTIC CLIP
TO REAR SMALL TRIM
SECURE FRONT END CAP
Taking note of the Track orientation shown in
Step 5, fasten the Track to the front nutsert in
roof channel through the front facing End Cap
hole using 1 x M6 Washer and 1 x M6 Button
Head Capscrew. Finger tighten screw.
16
x2
1
2

28-13-021-Rev1 10/15
RIVET REAR OF TRACK AND END CAP
Align rear of Track by inserting a Rivet through End Cap and Track into the previously drilled hole.
Secure using a Rivet Gun.
18
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 NEXT PAGES FOR BAR INSTALLATION
19

28-13-021-Rev1 11/15
BAR INSTALLATION
REMOVE LEG COVERS
Using the keys supplied in the
LOCKN’LOAD Leg Kit (sold separately),
remove all Leg Covers.
LEG ASSEMBLY
Apply a high strength (red) thread
locking compound* to the first half of
thread on each M8 Set Screw 16mm.
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.
12
34
6
Loosely finger tighten Nut Plates to
Legs as shown using the screw+washer
assemblies from the previous step.
For the next step, ensure there is a sufficient
gap between the Nut Plates and Legs.
5
Assemble 1 x M8 Washer onto each M8
Set Screw 16mm (with thread locking
compound applied).
The spring washers supplied in
the kit do not need to be used.
*Thread locking compound not supplied.
Complete the next steps as soon as possible, before
thread locking compound cures. Refer to thread
locking compound’s specification for curing time.
If bars are removed in the
future and legs repositioned,
thread locking compound
should be reapplied.

28-13-021-Rev1 12/15
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 8.
BAR LOCATION
IMPORTANT: Before
beginning Bar installation,
identify where along
the Track you want the
Rear Bars fitted. We
recommend a minimum
of 700mm between Bars.
NOTE - Bars require individual adjustment due to tapered
roof. Bars must be installed perpendicular to Tracks.
BAR SLOT COVERS
Cut Bar Slot Covers as per measurements recorded in the table above and insert into underside
channel of Bar ends as shown.
NOTE - Bar Slot Covers to be
inserted with flat side visible
Remove Legs from Bar once equal measurement is obtained
and recorded. Loosen the previously finger tightened screw
on each leg, keeping Nut Plate and Screw assemblies in
place as shown.
≥ 700mm
==
==
78BAR 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 Screw on each Leg to secure
Leg position along Bar. Repeat process for remaining bar
assemblies then carefully remove Bars from vehicle.
9
10
XX
YY
X = X
Y = Y
ZZ
Z = Z
BAR SLOT
MEASUREMENTS
Bar 1 (X)
______mm x2
Bar 2 (Y)
______mm x2
Bar 3 (Z)
______mm x2

28-13-021-Rev1 13/15
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 10, cut to
this length and insert into the underside channel of
each Bar end as shown.
12 13
14
15
-20mm
11

28-13-021-Rev1 14/15
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 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
16 17
18
20 21
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 Bars.
19
INSERT NUT PLATES
Run all M6 Hex
Screws through
Nut Plates to
remove burrs.
Insert one (1) Nut Plate
into each Front Track, and
two (2) Nut Plates into
each Rear Track via the
End Caps as shown.
33

28-13-021-Rev1 15/15
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.
22 23
24 25 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: