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

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

• Flat Blade Screwdriver

• 10mm Open Ended Spanner

• 13mm Socket or Spanner

• Rivet Gun

• Scissors

• Centre Punch

• Automotive Degreaser

• Automotive Adhesive

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.

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.

Vehicle Front

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.

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.

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

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

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

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.

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

-20mm

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.

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

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

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

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:

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