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Summary of Contents for Prorack K544
- Page 1 K544 Fitting Kit Fitting Instructions for Basic Carrier Revision No: 3C...
- Page 2 Fitting Kit K544 MAX kgs (lbs) Toyota Hilux Double Cab, 4dr Ute 05-12 75 kgs (165 lbs) 100 kgs (220 lbs) Hilux Double Cab, 4dr Ute 05-12 75 kgs (165 lbs) 100 kgs (220 lbs) Hilux Double Cab, 4dr Ute 05-12...
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Page 3: First Time Installation
Fitting Kit K544 Items you will require: Tape measure Flat-head screwdriver Craft knife Side cutters or tin snips Hammer 8mm (3/8") punch Cordless drill Depth stop Vacuum cleaner Rust inhibitor Small paint brush Neutral cure silicon sealant Rivet gun Attention: Attaches with riveted mounts under rubber ditch mould. - Page 4 Fitting Kit K544 This kit fits type A, B, C and D. These instructions show type A crossbar fitted. They also apply to type B, C and D. Use keys to remove covers. Use hex screwdriver to reverse adjusting screw 10 turns.
- Page 5 Fitting Kit K544 Press adjusting screw and pull crossbar legs out. Refer to the crossbar instructions for crossbar adjustment method. Ensure each end of the crossbar is adjusted equally. Adjust crossbar in or out to suit vehicle. Please check the front of this manual for information relating specifically to your vehicle.
- Page 6 Fitting Kit K544 Select plastic internal block (from fitting kit) and insert into foot. Repeat for all legs. Fit rubber pads (supplied with fitting kit) to foot. Pad may vary in shape to that shown. Make sure the pad fits into the holes underneath the foot.
- Page 7 Fitting Kit K544 Permanent Mount Fitment Carefully cut tape to seperate ditch mould from roof. Repeat for all four positions. Ditch mould held at each end by: A = Plastic retaining clip. B = Double sided tape. Apply protective tape as shown.
- Page 8 Fitting Kit K544 Unhook rubber ditch mould from plastic retaining clip (A) and double sided tape (B). Lift ditch mould up and out of the channel. Completely remove from the vehicle. The rubber ditch mould is to be re-installed on the vehicle later.
- Page 9 Fitting Kit K544 Carefully cut rubber ditch mould between faces along steel strip. A = Top face B = Bottom face A = Top B = Bottom C = Steel strip D = Removed excess Check fit.
- Page 10 Fitting Kit K544 Cut steel strip in centre using side cutters. Lift and cut steel strip at each end. Remove cut peices of steel strip. Repeat for all four positions. Turn rubber ditch mould over. Punch 8mm (3/8") hole through top of rubber ditch mould, centered on mark as shown.
- Page 11 Fitting Kit K544 Position as shown. Line up the centre hole in the mounting block with the marked reference points. Lightly mark position of outside holes of the mounting block in the roof channel. CAUTION: Maximum depth 7mm. Use 7mm drillstop over supplied 4.9mm drill bit.
- Page 12 Fitting Kit K544 Vacuum and clean swarf from channel. Treat holes to prevent corrosion. Apply neutral cure silicon sealant in and around drilled holes.
- Page 13 Fitting Kit K544 Install rivets through permanent mount blocks. Rivet into place. Fit plastic plugs to permanent mount blocks over rivet heads. Assemble as shown.
- Page 14 Fitting Kit K544 A = Double sided tape Apply as shown, at both ends of the roof. Re-install rubber ditch mould in roof channel. Remove all masking tape. Ensure the hole in rubber ditch mould lines up with mount.
- Page 15 Fitting Kit K544 Place crossbar on vehicle. Tighten the plastic knob. Ensure the plastic knob is in the position shown when fully tightened.
- Page 16 Fitting Kit K544 Tighten adjusting screw to 5 Nm (3.7 ft lb) hand tight. Check crossbar is securely attached to the vehicle. Use keys to fit and lock covers CAUTION: Recheck all fasteners immediately after a load is applied to the crossbars.
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Page 17: Maintenance
Fitting Kit K544 Maintenance Clean the car roof and surfaces of the product that will be in contact with the car roof. Follow the fitting instructions for fitting the product to your vehicle. Make sure all steps are carried out in order. - Page 18 Fitting Kit K544 Check and replace worn out or defective parts. Keep the product clean and maintained. Never drive into a car wash with the roof rack system fitted. Lubricate locks and adjusting screws at regular intervals. Remove the products from the vehicle when not in use.
- Page 19 Make a claim as soon as practicable by contacting the Prorack dealer from whom you purchased the product, who will give you instructions on how to proceed. If you are unable to contact the Prorack dealer, or the dealer is not able to remedy the defect, you should contact Yakima as soon as practicable at: Call: 0800 4776 722 (NZ) or 1800 143 548 (AU) Email: warranty@yakima.co.nz or warranty@yakima.com.au...
- Page 20 Yakima or the Prorack dealer will be borne by you. Following receipt of the product and purchase invoice or receipt, Yakima or the Prorack dealer must inspect the product to determine whether the claim falls within the warranty. If: 4.1 the claim falls within the warranty, Yakima will remedy any defects in materials or workmanship becoming apparent during the...
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