Yakima LOCKN'LOAD User manual

28-13-331-Rev1 1/11

LOCKN’LOAD TRACK MOUNTING KIT

TOYOTA FORTUNER GX 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

KIT CONTENTS

ITEM COMPONENT QTY ITEM COMPONENT QTY

1. Track Toyota Fortuner Right Hand Side x1 6. Rivet x18

2. Track Toyota Fortuner Left Hand Side x1 7. Drill Bit x1

3. Track Nut Plate x4 8. M6 Hex Screw x8

4. M6 Washer x8 9. End Cap Front Left & Rear Right x2

5. M6 Spring Washer x8 10. End Cap Front Right & Rear Left x2

MAX VEHICLE ROOF LOAD RATING: 100KG

TOTAL LOAD EQUALS WEIGHT OF ROOF RACKS + ACCESSORIES + CARGO

• 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:

• Flat Blade Screwdriver

• 10mm Open Ended Spanner

• 13mm Socket or Spanner

• Rivet Gun

• Scissors

• Centre Punch

• Automotive Degreaser

• Automotive Adhesive

• Thread Locking Compound

LEG AND BAR COMPONENTS SOLD SEPARATELY

28-13-331-Rev1 2/11

TRACK INSTALLATION

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 14.

TRACK MEASUREMENTS

Apply Masking Tape along roof channel.

Using a Tape Measure, measure

350mm back from the edge of the

windscreen as shown and record.

Vehicle Front

NOTE - image as viewed from rear of vehicle

2TRACK ORIENTATION

The extrusion on side of Tracks faces inside of vehicle as

shown, with rounded rectangular cut outs at rear of vehicle.

The help of an assistant is recommended to install Tracks.

It is recommended to install one Track at a time.

NOTE - image as viewed

from rear of vehicle

Extrusion

Vehicle Front

LEFT Track

RIGHT Track

Rounded rectangular cut

out at rear of vehicle

Apply lengths of Masking Tape

along window and door seals.

APPLY MASKING TAPE

NOTE - This prevents drill swarf from getting caught.

350mm

28-13-331-Rev1 3/11

ALIGN TRACK INTO ROOF CHANNEL

Place Track into roof channel, lining up the front of the track end with the tape line measured in

Step 3. Ensure Track orientation and spacing is correct as shown, with rounded rectangular cut

outs at rear of vehicle.

350mm

Extrusion

MARK TRACK HOLES

With the help of an assistant, hold Track down ﬁrmly in roof channel and mark all holes using a

Marking Pen. Ensure Track does not move during this process. Remove Track.

CENTRE PUNCH

HOLES

Using a Centre

Punch and

Hammer,

accurately Centre

Punch the holes

marked in the

previous Step.

7DRILL ROOF

Using the 4.9mm Drill Bit provided and

a Drill Stop which allows a drill depth

of 6-8mm, carefully drill through the

roof at each centre marked location.

Ensure a drilling angle perpendicular

to the roof surface is maintained

throughout.

Vehicle

Front

Pay extra attention when drilling

these holes. Always use a Drill Stop.

! !

Warning!

4mm

DRILL DEPTH

Drill Stop

6-8mm

28-13-331-Rev1 4/11

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.

Stage 1

Apply liberally

in and around

holes.

Allow to dry.

Stage 2

Apply liberally

in and around

holes.

PLACE TRACKS BACK INTO ROOF CHANNEL

Accurately place Tracks over drilled holes in roof channel, ensuring Track

orientation is correct as shown, with rounded rectangular cut outs at rear

of vehicle.

910

Extrusion

END CAP FITMENT

Assemble End Caps within Tracks as shown,

taking note of End Cap orientation.

Align End Cap and

slide into position

This edge faces

towards middle

of vehicle

28-13-331-Rev1 5/11

Align Track and secure End Caps by inserting all Rivets in their respective holes through Track into

roof channel.

Using a Rivet Gun, activate each Rivet starting from the centre Rivet, then working consecutively

outwards as shown.

TRACK INSTALLATION

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 on trim.

Remove trim from vehicle and cut to

length using a Fine Tooth 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

12 3

6 78 9

To secure End Caps,

insert Rivet through

End Cap and Track

Vehicle Front

CUT ROOF CHANNEL TRIM TO SIZE AND REFIT

28-13-331-Rev1 6/11

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 PAGE FOR BAR INSTALLATION

28-13-331-Rev1 7/11

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.

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.

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.

28-13-331-Rev1 8/11

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 8.

BAR LOCATION

IMPORTANT: Before

beginning Bar installation,

identify where along the

Track you want the Front

and Rear Bars ﬁtted. We

recommend a minimum of

700mm between Bars.

NOTE - Front and Rear 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 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

and recorded. Loosen the previously ﬁnger tightened screw

on each leg, keeping Nut Plate and Screw assemblies in

place as shown.

≥ 700mm

BAR SLOT MEASUREMENTS

Front Bar (X) Rear Bar (Y)

______mm x2 ______mm x2

X = X

Y = Y

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 for remaining

bar assembly then carefully remove Bars from vehicle.

28-13-331-Rev1 9/11

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

-20mm

28-13-331-Rev1 10/11

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.

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

16 17

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 Bar.

this

INSERT NUT PLATES

Run all M6 Hex

Screws through

Nut Plates to

remove burrs.

Insert two (2) Nut Plates into

each Track as shown.

Nut Plate

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