Introduction
Welcome to the instruction manual for your Yakima Tonneau Kit 1. This kit is designed to seamlessly integrate your Yakima OverHaul HD or OutPost HD truck rack with various tonneau covers, allowing you to maximize your cargo-carrying capabilities without compromising bed security.
Please read this manual thoroughly before installation and use to ensure proper setup, safe operation, and long-lasting performance of your product. Keep these instructions for future reference.
Safety First: Always ensure all components are securely fastened and regularly check for tightness, especially before and after long trips. Do not exceed the stated load capacities.
Product Overview
The Yakima Tonneau Kit 1 is an adapter kit that enables the use of Yakima OverHaul HD and OutPost HD truck racks with specific tonneau covers. This robust solution provides a secure and versatile platform for hauling gear while maintaining the functionality of your truck bed cover.
- Versatile Compatibility: Adapts Yakima OverHaul HD and OutPost HD truck racks to fit Retrax XR Series, Embark LS, and Pace-Edwards UltraGroove tonneau covers (except 2004+ Ford F-150).
- Robust Construction: Made with high-quality aluminum and corrosion-resistant hardware, built to withstand harsh conditions and provide long-lasting durability.
- Secure Load Capacity: Supports up to 300 lbs. on-road and 180 lbs. off-road, ideal for heavy-duty hauling.
- Integrated Security: Features Yakima's SKS (Same Key System) locks to secure your rack system to the tonneau cover.
Figure 1: Components of the Yakima Tonneau Kit 1, including adapter plates, T-bolts, and wrench.
Figure 2: Key dimensions and weight of the adapter kit.
Figure 3: Overview of the adapter kit's features, including compatibility, aluminum construction, and load capacities.
Setup and Installation
Follow these steps to properly install your Yakima Tonneau Kit 1 and integrate it with your truck rack. For a visual guide, please refer to the official installation video below.
Official Yakima Tonneau Kit 1 Adapter Kit Installation Video. This video provides a step-by-step visual guide for installing the adapter kit and integrating it with your truck rack system.
- Prepare Tonneau Rails: Clean the T-slots on your tonneau cover rails to ensure a clear path for the T-bolts.
- Insert T-Bolts: Insert four T-bolts into each of the tracks on the sides of your tonneau cover. Slide them to the approximate positions where your OverHaul HD or OutPost HD towers will be installed.
- Position Base Pads and Towers: Place the base pads over the T-bolts. Then, carefully place the towers over the base pads and the bolts, ensuring that the long sides of the tower bases face each other.
- Install Hardware Loosely: Attach the acorn nuts to the T-bolts, but do not tighten them fully at this stage.
- Install Locking Pin: Insert a locking pin into the designated hole on each tower base.
- Measure and Position Towers:
- Using a measuring tape, measure from the cab of your truck to the front tower bases. Adjust them so they are equally aligned.
- Position your rear towers and measure them from the front towers. Ensure they are equally spaced and allow for a crossbar spread of at least 36 inches for optimal stability and load distribution.
- Tighten Acorn Nuts: Once the towers are correctly positioned, tighten the acorn nuts using the included 13mm wrench. Ensure they are snug but do not overtighten.
- Tighten Lock Nuts: Secure the lock nuts with the 4mm wrench that came with your Outpost HD or OverHaul HD rack.
- Install Accessory Lock Housing: To fully secure your Outpost HD or OverHaul HD, grab your accessory lock housing. Remove the underside screw with the T15 Torx wrench and install the lock housing.
After completing these steps, your Tonneau Kit 1 is installed. Proceed with the full installation of your HD truck rack according to its specific instructions.
Figure 4: The Tonneau Kit 1 allows full access to your truck bed even with the rack installed.
Figure 5: Example of a Yakima rack system installed with the Tonneau Kit 1, carrying a ladder.
Figure 6: Detailed view of the rack base securely mounted on the tonneau cover rail.
Operation
Once installed, the Yakima Tonneau Kit 1 allows your OverHaul HD or OutPost HD truck rack to function as intended, providing a stable and secure platform for transporting various loads. Always adhere to the specified load capacities:
- On-Road Load Capacity: Up to 300 lbs.
- Off-Road Load Capacity: Up to 180 lbs.
Ensure all cargo is properly secured to the rack using appropriate tie-downs or straps. Regularly check the security of your load during transit.
Maintenance
To ensure the longevity and optimal performance of your Yakima Tonneau Kit 1, regular maintenance is recommended:
- Regular Inspection: Periodically inspect all bolts, nuts, and components for tightness and signs of wear or damage. Tighten any loose fasteners.
- Cleaning: Clean the adapter kit and rack components with mild soap and water. Avoid harsh chemicals that could damage the finish or materials.
- Corrosion Check: Although made with corrosion-resistant hardware, inspect for any signs of rust or corrosion, especially in areas exposed to harsh weather conditions.
- Lubrication: If any moving parts (though minimal in this kit) become stiff, apply a small amount of silicone-based lubricant.
Troubleshooting
If you encounter any issues with your Yakima Tonneau Kit 1, consider the following:
| Problem | Possible Cause | Solution |
|---|---|---|
| Rack feels unstable or loose. | Loose mounting hardware. | Check and tighten all acorn nuts and lock nuts according to installation instructions. Ensure T-bolts are properly seated in the tonneau rails. |
| Difficulty sliding T-bolts in rails. | Debris in T-slots or misaligned bolts. | Clean tonneau T-slots thoroughly. Ensure T-bolts are inserted correctly and not binding. |
| Damage to tonneau cover rails. | Overtightening of mounting hardware. | Avoid overtightening. Tighten only until snug and secure. If damage has occurred, contact your tonneau cover manufacturer for repair or replacement options. |
| Accessory lock housing not fitting. | Incorrect screw removed or misalignment. | Ensure the correct underside screw (T15 Torx) is removed. Align the lock housing carefully before attempting to install. |
If problems persist, please contact Yakima customer support for further assistance.
Specifications
- Brand: Yakima
- Model Number: 8001155
- UPC: 736745011550
- Material: Aluminum
- Item Weight: 2.64 pounds
- On-Road Load Capacity: 300 lbs.
- Off-Road Load Capacity: 180 lbs.
- Compatibility: Yakima OverHaul HD, OutPost HD truck racks; Retrax XR Series, Embark LS, Pace-Edwards UltraGroove tonneau covers (excluding 2004+ Ford F-150)
Warranty and Support
Yakima products are built to last and are backed by a limited lifetime warranty. For detailed warranty information, product registration, or technical support, please visit the official Yakima website or contact their customer service department.
Online Support: www.yakima.com/support
Contact: Refer to the Yakima website for current contact methods (phone, email, chat).