KAWASAKI VULCAN 800 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install the heat shield to the front head pipe using the three hose clamps (supplied). Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 3. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 4. Be sure the steel spacers are in place in the center of the grommets. Install the two allen bolts (from removal step #3) through the mounting bracket and into the frame. Leave them loose at this time. 5. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time.

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2006 KAWASAKI KX450F Service Manual

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Filed Under (Kawasaki) by admin on 16-12-2010

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Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench. Force Use commonsense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have anon -permanent locking agent applied using an impact driver. Use aplastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets andO-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-ringswhenre-assembling Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket ora Non-permanent Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or Non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage. Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing

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CHANGING OIL IN THE KAWASAKI VULCAN VN 2000

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Filed Under (Kawasaki) by admin on 16-12-2010

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CHANGING OIL IN THE KAWASAKI VULCAN VN2000 ( based on a 2005 model) by tensm an1 Preparing the motorcycle: 1. To start, level the motorcycle – my preference is to put a spacer blocks under the kickstand on the left side of the motorcycle and under the frame on the right side of the bike just under the frame member. These blocks are made from scrap lumber. I find it is easier to set the right side block first as shown and tilt the motorcycle until the frame contacts the block, then, holding the handlebars, kick the left side block under the kickstand. 6″ NOTE: This dimension may not be correct for 2004 models as the 2005 models have a different kickstand – the 2004 model will likely be thicker. To be sure your blocks are the correct thickness the first time, lay a level across the luggage rack as shown. You may need to shim them slightly to hold the bike dead level. 2 7/8″”
Or, in the absence of a luggage rack, the seat will do: 2. Get the necessary tools ready: Oil filter wrench – I like the band type shown, but a metal strap type will work. 14 mm box wrench

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KAWASAKI 1700cc Liquid-Cooled V-Twin Engine 6-Speed Transmission with Overdrive

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Filed Under (Kawasaki) by admin on 13-12-2010

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Kawasaki’s first production bagger model is ready to take the street by force. The new Vulcan® 1700 Vaquero™ motorcycle combines the authority of a massive 1700cc liquid-cooled V-Twin engine together with low-slung, streetwise styling of a frame-mounted front cowling and lower chin fairing, sleek side-opening hard bags, and a choice of stealthy Ebony or fiery Candy Fire Red monotone paint. Besides its unmistakable style, the Vaquero also includes a smooth-shifting 6-speed overdrive transmission, cruise control, a full-feature audio system, and a host of custom-designed accessories. Get ready to rumble. 1700cc Liquid-Cooled V-Twin Engine The Vulcan 1700 Vaquero’s 1700cc V- Twin bristles with low-rpm torque, ensuring immediate and potent acceleration. 6-Speed Transmission with Overdrive With its overdrive top gear, the Vaquero’s 6-speed transmission teams up with the V-Twin engine for a relaxed highway cruising experience. Frame Mounted Front Cowling Muscular front cowling features a cut-down windscreen for a minimalist look and uninterrupted airflow, and is frame-mounted for light handling. Side-Opening Hard Bags Holding an impressive 9.2 gallons of storage apiece, the side bags integrate neatly into the Vaquero™’s smooth, clean lines. Electronic Cruise Control Conveniently located on the right handlebar, the Vaquero’s standard electronic cruise control precisely maintains speeds between 30 and 85 mph. Full-Feature Audio System High-fidelity audio system features AM/FM and weather radio, and is can be accessorized with iPod players, XM Radio and CB radios. Multi-Function LCD Instrumentation Located on the Vaquero’s stylish “muscle car” inspired dashboard, the multi-function LCD instrumentation clearly organizes and presents all essential information.
Engine Four-stroke, liquid-cooled, SOHC, four valve per cylinder, 52° V-twin Displacement 1,700cc / 103.7ci Bore X Stroke 102 x 104mm Compression Ratio 9.5:1 Maximum Torque 108 lb-ft @ 2,750 rpm Cooling System Liquid, plus cooling fins Ignition TCBI with Digital Advance Induction Digital fuel injection, dual 42mm throttle bodies Transmission 6-speed with overdrive and positive neutral finder Frame Type Steel, double-cradle with box-section single-tube backbone Rake/Trail 30° / 7.0 in. Front Suspension / Wheel Travel 45mm hydraulic fork / 5.5 in. Rear Suspension / Wheel Travel Swingarm with twin air-assisted shocks, with 4-way rebound damping / 3.1 in. Front Tire Size 130/90×16 Rear Tire Size 170/70×16 Brakes, Front / Rear Dual 300mm discs, dual twin-piston calipers / Single 300mm disc, twin-piston caliper Overall Length 98.8 in. Overall Width 38.2 in. Overall Height 50.8 in. Seat Height 28.7 in. Curb Weight 835.7 lbs.** Wheelbase 65.6 in. Fuel Capacity 5.3 gal. Color Choices Ebony, Candy Fire Red Warranty 36 months Good Times™ Protection Plan 12, 24 or 36 months ** Curb weight includes all necessary materials and fluids to operate correctly, full tank of fuel (more than 90-percent capacity) and tool kit (if supplied

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2011 Ninja ZX-10R Review And SPECIFICATIONS

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Filed Under (Kawasaki) by admin on 13-12-2010

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1. Big Piston Fork (BPF) and Öhlins Steering Damper Throwing out the anchors at track speed demands a fork that remains composed under pressure. The fully adjustable new Big Piston Fork (BPF) does just that by significantly reducing damping pressure while maintaining consistent damping force. The standard Öhlins Steering Damper is likewise adjustable to help you dial in the steering damping level you need. 2. Horizontal Back-Link Rear Suspension New rear suspension positions the shock and its linkage above the swingarm, leaving room beneath the bike for a larger exhaust pre-chamber. The move helps centralize mass for better transitional cornering response, while also improving overall suspension action and road holding. The piggyback-reservoir shock is fully adjustable, including both low- and high-speed compression-damping circuits. 3. Adjustable Footpegs Adapting the ZX-10R for a day at the track or a long street ride is easy, thanks to its new adjustable footpegs. Raise the footpegs to improve your cornering clearance on the track, or lower them for a more relaxed riding position on the street or highway. The total range of adjustment is 15mm. 1. 2. 3. SPECIFICATIONS Engine Four-stroke, liquid-cooled, DOHC, four valves per cylinder, inline-four Displacement 998cc Bore X Stroke 76.0 x 55.0 mm Compression Ratio 13.0:1 Fuel System DFI® with four 47mm Keihin throttle bodies with oval sub-throttles, two injectors per cylinder Ignition TCBI with digital advance and Sport-Kawasaki Traction Control (S-KTRC) Transmission Six-speed Final Drive Chain Rake/Trail 25.0deg / 4.33 in. Front Tire Size 120/70 ZR17 Rear Tire Size 190/55 ZR17 Wheelbase 56.1 in. Front Suspension / Wheel Travel 43mm inverted Big Piston Fork (BPF) with DLC coating, adjustable rebound and compression damping, spring preload adjustability / 4.7 in. Rear Suspension / Wheel Travel Horizontal Back-link with gas-charged shock and top-out spring, stepless, dual-range (low-/high- speed) compression damping, stepless rebound damping, fully adjustable spring preload / 4.9 in. Front Brakes Kawasaki Intelligent anti-lock Braking (KIBS), dual semi-floating 310mm petal discs with dual four-piston radial-mount calipers Rear Brakes KIBS-controlled, single 220mm petal disc with aluminum single-piston caliper Fuel Capacity 4.5 gal. Seat Height 32.0 in. Curb Weight TBD Overall Length 81.7 in. Overall Width 28.2 in. Overall Height 43.9 in. Color Choices Lime Green / Ebony, Ebony / Flat Ebony Warranty 12 Months Good Times™ Protection Plan 12, 24, 36, 48 months PERFORMANCE PARTS Kawasaki offers a full line of performance parts for your new motorcycle. COVER Constructed of water-resistant polyester and a unique shielded vent system that allows built-up moisture to vent. Reinforced grommet at the bottom hem allows the cover to be locked to the bike for added security. Heat resistant panels in the exhaust area. Oversized fit allows for easy installation and removal.

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KAWASAKI ZZR 1400 SPECIFICATIONS/ FEATURES AND BENEFITS

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Filed Under (Kawasaki) by admin on 04-12-2010

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Engine type . …………………….. 4-stroke, liquid-cooled, in-line 4 Displacement . ………………….. 1352 cm3 Bore x stroke . ………………….. 84.0 x 61.0 mm Compression ratio . ………….. 12.0: 1 Valve system . ………………….. DOHC, 16 valves, 4 valves per cylinder Maximum power . ……………… 140 kW (190 PS) / 9,500 r/min (Fr. 78.2 kW (106 PS) / 8,500 r/min) Maximum power + ram air . .. 147 kW (200 PS) / 9,500 r/min Maximum torque . …………….. 154 N•m / 7,500 r/min (Fr. 114 N. m / 4,500 r/min) Fuel system . ……………………. EFI with 4 x 44 mm Mikuni throttle bodies Ignition . …………………………… digital TCBI (ECU controlled) Starting system . ………………. electric Transmission . ………………….. 6-speed Frame type . ……………………… aluminium monocoque Rake / trail . ………………………. 23″ / 94 mm Suspension, front . ……………. 43 mm inverted fork Suspension, rear . …………….. Uni-Trakfi with gas-charged shock absorber Wheel travel, front / rear . ….. 117 / 122 mm Tyre, front / rear . ………………. 120/70 ZR 17 / 190/50 ZR 17 Brake, front . …………………….. 310 mm dual discs with radial mount 4-piston calipers Brake, rear . ……………………… 250 mm disc with single piston caliper L x W x H . ………………………… 2,170 x 760 x 1,170 mm Wheelbase . ……………………… 1,460 mm Seat height . ……………………… 800 mm Fuel capacity . ………………….. 22 L Dry weight . ………………………. ZX1400A6F 215 kg / ZX1400B6F 218 kg Colours . …………………………… Pearl Meteor Grey or Candy Thunder Blue Kawasaki 2006 SUPER SPORTS 5 ZZR1400 (ZX1400A6F/B6F) FEATURES AND BENEFITS ENGINE 1352cm3 4-cylinder DOHC engine ! The most powerful production Kawasaki motorcycle engine ever. ! All new compact 4-cylinder engine. ! Gear-driven dual secondary balancers cut vibration, minimising engine wear, noise and rider fatigue. ! Chrome composite plated cylinders are lightweight, durable, and quickly carry heat away from the combustion chamber and piston for supreme durability at high power output. Fuel system ! Electronic fuel injection feeds the engine exactly the right amount of fuel giving excellent power, fuel economy, driveability and starting. ! High atomising injectors are used to maximise combustion efficiency and minimise emissions. ! Dual throttle valves are fitted to significantly improve driveability. The sub throttle valves are controlled by the ECU to provide precise response. ! An oval throttle pulley improves throttle control, opening less initially but increasing as more throttle is applied. ! ECU is a 32 bit unit to provide the control circuit required to operate the dual throttles. ! The ram air induction system takes cooler, high- pressure air from in front of the cowling and pushes it through the air cleaner and into the engine for maximum power output. ! To minimise emissions, honeycomb-type catalysers are used.

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1982 Kawasaki KZ550C Electric Motorcycle Conversion Notes

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Filed Under (Kawasaki) by admin on 03-12-2010

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Starting point: • 1982 Kawasaki KZ550C that I found in an alley near my house. Frame rust sanded and repainted. • Rebuilt front suspension ($25 for front fork oil seals, 1 weekend for repair) • Need-to-be-rebuilt front brake caliper • Need-to-be-replaced front master brake cylinder (expected ~$80) • Need-to-be-refurbished electrical wiring system and 12V battery • Working rear brake • Flat rear tire, patched with fix-a-flat (temporary repair), 77″ circumference. • In-tact 530 size 62″ chain with 36 tooth driven sprocket • Miscellaneous spare parts from 1978 Kawasaki KZ450, most of which fit on the 1982 frame, including an ignition switch and key. I started with a chassis I found in an alley near my house. It was in rough shape and needed some refurbishment before I could start the conversion. Most of refurbishment steps are listed above in bullets. In addition to the repainting and repair of important aspects of the bike, I also needed to remove the IC engine components and the grease caked on from years of IC use. The Clymer manual for this bike was helpful in this process, which was about $18 from [13]. Steps for removing the engine were as follows. I removed the seat and the gas tank. I removed the electrical system wiring and 12V battery holder. I then removed the carburetors (which took a lot of pushing and shoving) and air filter box. I then removed the drive socket cover and removed the drive socket from the engine drive shaft. This allowed me to slip the chain off of the drive socket after loosening the rear wheel to put slack into the chain. I slipped the chain off and let it rest on the rear wheel swing arm and drained the old motor oil. I then removed all of the engine mounting bolts and pushed the entire engine out of the right side of the bike. This took a lot of effort but it is possible to remove the engine without removing the piston heads as recommended in the Clymer manual. The engine weights about 60-70 lbs, so it was possible to handle with one person. I suggest using a flat car jack to help with engine removal. I will eventually sell the IC parts through Ebay

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2006 KAWASAKI KX250F Service Manual

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Filed Under (Kawasaki) by admin on 02-12-2010

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Gasket, Oring Hardening, shrinkage, or damage of both gaskets andO-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-ringswhenre-assembling Liquid Gasket, Locking Agent For applications that require Liquid Gasket ora Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage. Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. GENERAL INFORMATION 1-5 Before Servicing Ball Bearingand Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage. Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing. Apply specified grease to the lip of seal before installing the seal.

1984 KAWASAKI GPz900R Restoration Project

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Filed Under (Kawasaki) by admin on 01-12-2010

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The paint work on the motorcycle is the original “Red & Gun Metal Grey” but is so badly worn with the outer layer of clear missing and hence all body work requires re-painting. The tank has undergone the usual repair on the left hand side since rust has eaten into the bottom corner from water being in the fuel and the paint has been worn of where the riders legs rub.. The rear tail piece is structurally ok but features worn paint. The right hand side cover has a broken stud and the left hand side cover has a heat warp under the tank. The lower fairing is damaged, the middle fairing is missing one decal on the right hand side and the top fairing has small cracks from a possible accident. The wind screen is worn and faded and will require replacement. The seat has been taped together and requires recovering. Figure 1 Body Work in original state. 1984 GPz900R Schedule of Work 4 of 20 1.2.2 Engine The engine has 90,000 klms on it according to the instruments which appear to be original. The engine was sold with a defective starter clutch as it appears to spin but initial attempts to start the engine failed. A replacement starter clutch is in storage and to refit the part requires that the engine be removed, inverted, bottom engine case removed and all assemblies removed until the starter clutch become accessible rather than a total rebuild. The engine was last run in 2005 and appears to be in good external condition. The condition of the carburetors is unknown but will need to be stripped and cleaned as a service exercise. 1.2.3 Suspension and Brakes On arrival a rust spot with a diameter of 5 cm was noted on the left fork and it was determined that the forks must undergo hard chroming to remove the rust and any chips. The fork seals are damaged but replacements have been supplied. An inspection of the disks revealed worn disks front and rear. New disks are available and will be required. The condition of the brakes appears to be poor but for a bike that has had no services performed this is to be expected. The image below shows the state of the motorcycle at time of purchase

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Kawasaki KLR Lowering Kit Installation Instructions

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Filed Under (Kawasaki) by admin on 01-12-2010

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locate the OEM tie rods (circled in yellow, in the picture below), and the rear shock absorber snubber (circled in red, in the picture below). Notice that there is a tie rod on each side of the motorcycle. These tie rods are secured by two long bolts that pass first through the LH tie rod, then through the suspension, and finally held in place by two 17mm nuts on the RH side. Loosen these two 17mm bolts, and prepare them for removal. It helps to raise the rear tire just slightly with a jack or by a helper, to take the load off of these 17mm bolts. Below is another picture, better exposing the orange rubber snubber on the lower shock absorber rod… This is where the snubber spacers are installed, but don’t do it just yet…there’s more info on this later in the instructions. 3. Remove the 17mm nuts from the tie rods, keep the weight off of the rear wheel, and remove the upper and lower bolts from the tie rods. The rods are easily removed at this point. Take notice that the LH rod has recesses in each end, where the heads of the 17mm securing bolts fit. 4. Replace the tie rods with the new Scootworks tie rods in your kit. Install the tie rod with the recessed bolt holes on the LH side, with the recesses facing outward. Re-install the bolts from the LH side, through the LH tie rod, through the suspension, and through the RH tie rod. Secure them with the original nuts, and torque to 43 ft/lbs. The recessed bolt holes in the LH tie rod are seen in the picture of the Scootworks KLR tie rods below… 5. Do not install the plastic snubber spacers at this time. Lower the rear of the bike and remove the frame from the lift or jack stands. The rear lowering is completed. Sit on the motorcycle and determine if you’ve lowered it to a satisfactory level. If not, proceed to step #6. Your Scootworks KLR Lowering Kit is now installed. The following information is supplied as a supplement, to allow you to complete the job of lowering your bike that you’ve begun by using this Quality Scootworks product. NOTE: Be sure to check the chain tension after installation of the lowering kit, and adjust as necessary. Tips for setup and use of your lowering kit BE SURE to read the FAQ at the end of this document, for tips, warnings, and adjustments for your new lowering kit! Lowering the Front of your KLR-series Motorcycle

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