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Summary of Contents for Whispbar K991W
- Page 1 K991W Fitting Kit Fitting Instructions for Basic Carrier CAUTION: Professional installation recommended Revision No: 1A...
- Page 2 Fitting Kit K991W MAX kgs (lbs) Toyota Hilux Double Cab, 4dr Ute 16-+ 75 kgs (165 lbs) 100 kgs (220 lbs) Hilux Double Cab, 4dr Ute 16-+ 75 kgs (165 lbs) 100 kgs (220 lbs) Hilux Double Cab, 4dr Ute Oct 15-+...
- Page 3 Fitting Kit K991W Hilux Double Cab, 4dr Ute 16-+ (ZA) -125mm 620mm 885mm 880mm -4 -15/16ths" 24 7/16ths" 34 13/16ths" 34 5/8ths" Hilux Double Cab, 4dr Ute 16-+ (EU) -125mm 620mm 885mm 880mm -4 -15/16ths" 24 7/16ths" 34 13/16ths" 34 5/8ths"...
- Page 4 Fitting Kit K991W 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.
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Page 5: First Time Installation
Fitting Kit K991W First Time Installation Remove parts from inside the package and check. Contact your dealer if any parts are missing or damaged. 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. - Page 6 Fitting Kit K991W Use hex screwdriver to reverse adjusting screw 10 turns. 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.
- Page 7 Fitting Kit K991W Remove plastic clamp block by gripping bar leg with fingers and push firmly with thumbs until clamp block drops out behind leg. Select plastic internal block (from fitting kit) and insert into foot. Repeat for all legs.
- Page 8 Fitting Kit K991W Permanent Mount Fitment Carefully cut tape to seperate ditch mould from roof. Repeat for all four positions. Line up the centre hole in the mounting block with the marked reference points. Wrap tape around rubber ditch mould to mark end position of mount.
- Page 9 Fitting Kit K991W Apply protective tape as shown. Carefully remove ditch mould at the front position with flat-head screwdriver. Unhook rubber ditch mould from plastic retaining clip (A) and double sided tape (B). Lift ditch mould up and out of the channel.
- Page 10 Fitting Kit K991W 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 11 Fitting Kit K991W 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 12 Fitting Kit K991W Removed excess 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.
- Page 13 Fitting Kit K991W Note: Assemble as shown. CAUTION: RECOMMENDED POSITION DUE TO AIRBAGS IN ROOF: Please check the front of this manual for information relating specifically to your vehicle. CAUTION: Maximum depth 8mm. Use 8mm drillstop over supplied 4.9mm drill bit.
- Page 14 Fitting Kit K991W Treat holes to prevent corrosion. Apply neutral cure silicon sealant in and around drilled holes. Install rivets through permanent mount blocks. Rivet into place.
- Page 15 Fitting Kit K991W Apply as shown. Rear: Double sided tape Re-install rubber ditch mould in roof channel. Remove all masking tape. Ensure the hole in rubber ditch mould lines up with mount.
- Page 16 Fitting Kit K991W Select grubscrews and screw into the vehicle's fixed points. Do not over tighten. Repeat for all four positions. Refer to the underside of the pad for the part number. It is important to put the pads in the correct position on the vehicle.
- Page 17 Fitting Kit K991W 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. Place crossbar foot over grubscrews. Tighten the plastic knob.
- Page 18 Fitting Kit K991W Ensure the plastic knob is in the position shown when fully tightened. Tighten adjusting screw to 2 Nm (1.5 ft lb) hand tight. Check crossbar is securely attached to the vehicle. Use keys to fit and lock covers...
- Page 19 Fitting Kit K991W CAUTION: Recheck all fasteners immediately after a load is applied to the crossbars. Regularly check screws are tight.
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Page 20: Maintenance
Fitting Kit K991W 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 21 Fitting Kit K991W 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 22 Make a claim as soon as practicable by contacting the Whispbar dealer from whom you purchased the product, who will give you instructions on how to proceed. If you are unable to contact the Whispbar 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 23 Yakima or the Whispbar dealer will be borne by you. Following receipt of the product and purchase invoice or receipt, Yakima or the Whispbar 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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