Yakima LOCKN’LOAD Manual 

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 1 2 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 TM ® • 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 3 8 4 10 9 7 6 5 LEG AND BAR COMPONENTS SOLD SEPARATELY

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 2 TRACK 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 3 4 Apply lengths of Masking Tape along window and door seals. APPLY MASKING TAPE NOTE - This prevents drill swarf from getting caught. 350mm

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. 5 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. 6 CENTRE PUNCH HOLES Using a Centre Punch and Hammer, accurately Centre Punch the holes marked in the previous Step. 7 DRILL 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. 8 Vehicle Front Pay extra attention when drilling these holes. Always use a Drill Stop. ! ! Warning! 4mm DRILL DEPTH Drill Stop 6-8mm

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. 9 10 Extrusion END CAP FITMENT Assemble End Caps within Tracks as shown, taking note of End Cap orientation. Align End Cap and slide into position 12 11 This edge faces towards middle of vehicle

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 13 14 1 2 3 4 5 6 7 8 9 To secure End Caps, insert Rivet through End Cap and Track Vehicle Front CUT ROOF CHANNEL TRIM TO SIZE AND REFIT

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 15

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. 1 2 3 4 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.

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 X = X Y = Y 7 8 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 Screw on each Leg to secure Leg position along Bar. Repeat for remaining bar assembly then carefully remove Bars from vehicle. 9 10

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

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 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 Bar. this 19 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 33

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: