how to set valves on 2011 kawasaki teryx

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Filed Under (Kawasaki) by admin on 25-10-2010

1. Remove both seats from the vehicle. Next, remove the passenger side lower body panel. There is a mixture of Philips head screws and also plastic push pin fasteners that have to be removed. 2. With the side panel off, the next item to remove is the plastic housing over the engine. These are all “push in” style plastic clips that hold it in place. Once all the pins are out, you can slide the housing off and set it aside. 3. Now the lower long plastic panel under the seat has to be removed (again mainly plastic push clips to remove) . Once they are all out, carefully remove and set aside. 4. Next, remove the fuel tank. Remove the two lines on the top of the tank. There are two straps that hold the tank in place. Remove the bolt from each strap, remove the straps, and lift the fuel tank out. 5. Now the bracket that holds the fuel pump on has to be removed. There are two bolts here to take out. Once this is done, mark the two wires to the coil and disconnect them. Set the bracket out of the way . 6. Next, the clutch cover bolts can be removed and the norkel on the housing can be loosened and i Teryx 750 Clutch Kit Instructions 5/1/09 removed. Take the clutch cove off and set out of the way. 7. With the clutch visible, you can remove the secondary clutch with a large impact wrench and metric socket . 8. Remove the bolt from the primary clutch. This is a left hand thread on the bolt. Next you will need a Kawasaki drive clutch puller (part #352251) to pop the clutch loose. If you do not have a puller, the spring cap can be removed on the vehicle and the weights can be changed out in there as well. 9. With the clutches sitting on the bench, remove the bolts that hold on the spring cover. Remove the stock spring and the stock weights 10. After reading the directions on the new weights, add the correct amount of weight to each clutch weight and install them in the clutch. Place the weight to the left side in the clutch pocket and then install the aluminum spacer. Repeat this process for the other three weights. 11. Install the new spring supplied in the kit and install the spring cover, paying close attention to the arrows on the cover. 12. Next, remove the stock spring from the secondary. It is recommended that you use the TEAM Compression tool (part # 930001) for this. With the clutch on the compression tool, compress the spring retainer down far enough to remove the snap ring with the needle-nose pliers . Slowly back off the t-handle and remove the tool.

Kawasaki Teryx Skid Plate Installation And Removal Instructions


Filed Under (Kawasaki) by admin on 25-10-2010

1. Let skid sit in sun or inside house at room temperature for a couple hours. Cold weather can shrink plastic slightly but this is not an issue once installed. 2. Remove Stock Teryx Hardware/skids and set aside hardware to use on new skid 3. You have a couple options in mounting the new skids. 1) remove stock metal engine inspection cover underneath Teryx, or 2) using UHMW skid as template cut out hole in inspection cover (A below) to allow access to oil filter. Cut hole substantially larger than skid hole so as not to cut yourself when removing/installing oil filter 5. Fasten all main skid bolts and washers, but do not tighten all the way so that you are able to move skid slightly to center all bolt holes. 6. Fasten all front and rear skid bolts and washers, but do not tighten all the way so that you are able to move skid slightly to center all bolt holes. . Once skids are in desired location tighten all bolts 9. You will be required to drill 2 – 3/16 pilot holes in the 2 rear most main skid mounting locations. Use the supplied self tapping bolts and washers to attach skid in these locations

Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Upgrading the Suspension on the Kawasaki ER6-F/ N


Filed Under (Kawasaki) by admin on 30-11-2010

Top fork is as removed. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Before removing the fork from the clamps on the yokes I loosened the fork top. Before removing the fork top the fork-slider was placed in a vice and the bottom bolt loosened….. … before finally being removed with the fork upside down. Because the springs were still in situ this gave sufficient tension on the damper-rod to prevent it from turning and allow the bolt to be removed. When I turned the fork the right-way up to remove the fork-top I did it over a container to catch the oil. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource All the OE components that will no longer be required. Left to right. Fork-top, spacer tube, washer, spring, damper-rod. Bottom bolts get re-used. Old and new, laid-out for comparison. The damper unit, minus spring and fork-top, drops inside the stanchion and slider. Kawasaki Ninja 650R (ER-6F) & ER-6N Resource Then the bolt goes back in, as tight as possible, to secure it. Top fork is done, second one awaits. Note the spring seat on the right, just below the spring. This drops over the damping rod after the oil has been added. The small locking-nut screws over the threaded part of the damping-rod next, all the way to the bottom. Spring drops in and then the fork-top screws on to the damping-rod as well, all the way down to the lock-nut which is used to secure it. At this point the stanchion is extended to the fork-top which is screwed in. Job done.

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Kawasaki FI Calibration Tool Instruction Manual


Filed Under (Kawasaki) by admin on 08-02-2011

System Function Kawasaki FI Calibration Tool (FI Tool) is developed to modify the mapping of the racing machine to gain operating conditions suitable for the course and the rider’s skill. The following are the available setting functions. Table 1 FI Tool Function Model Name Functions Available Setting Range ’04 ZX-10R ’05 ZX-6RR ’05 ZX-10R ’06 ZX-10R ’07 ZX-6R 1) Adjust the injected fuel rate at acceleration -30 % ~ +30 % 〇 〇 〇 〇 〇 2) Adjust the injected fuel rate of No.1 and No.4 cylinder -30 % ~ +30 % 〇 〇 〇 〇 〇 3) Adjust the injected fuel rate of No.2 and No.3 cylinder -30 % ~ +30 % 〇 〇 〇 〇 〇 4) Adjust the injected fuel rate of primary and secondary injector * -30 % ~ +30 % -10 % ~ +10 % — – — 〇 — – — – — 〇 5) Adjust the ignition timing -15°CA~ +5°CA 〇 〇 〇 〇 〇 6) Adjust the sub-throttle opening angle -50 % ~ +50 % -45 % ~ +45 % 〇 — – 〇 〇 — 〇 — – 〇 7) Adjust the exhaust device opening angle -50 % ~ +50 % 〇 — 〇 〇 — 8) Adjust the all injected fuel rates of all cylinders and operating are a simultaneously -30 % ~ +30 % 〇 〇 〇 〇 〇 9) Adjust the value of engine over revolution limiter 0 ~ +300 rpm -1000 ~ +700rpm -1000 ~+1200rpm — – — 〇 — – — 〇 — – — 〇 〇 — – 10) Set the fuel cut or not at deceleration Use or Not Use 〇 〇 〇 〇 〇 11) Set the sub throttle controlled or not Controlled or Full Open Fixed 〇 — – — – 12) Set the exhaust device controlled or not Controlled or Full Open Fixed 〇 〇 〇 〇 〇 13) Set the Auto Shifter Ignition Cut Length Controlled or not, set Ig. Cut Time by gear range — – 〇 〇 〇 14) Set the Pit Road RPM Limit Controlled or not, set Upper Limit RPM by gear range



Filed Under (Kawasaki) by admin on 25-10-2010

a. Remove rubber boot from the back of the headlamp housing assembly. b. Push down on metal latch and pull away from lip to release halogen bulb. Pull out halogen bulb. c. Insert HID bulb, line up bulb to fit into the bulb holder, lower latch to lock bulb in place. d. Replace Rubber boot on the back headlamp assembly. (Make sure to pull wires through the center of the rubber boot first before you start to pull down boot on the back of the headlamp assembly.) e. Make sure that the wiring, coming from the HID bulb, clears the black plastic housing that encases the headlamp assembly so connection from the bulb to the ballast is possible. If installed correctly there is no need for drilling or modifications of any type. 2. Ballast a. Mount ballast in location of your choice – recommended near the headlight. 3. Wiring Note: DO NOT modify the wiring that runs from the HID bulb to the ballast. It will cause the system to work improperly. It will void the warranty . a. Once ballast is installed connect corresponding wires from HID bulb to corresponding male / female plugs on ballast. b. To connect wiring from ballast to Teryx primary system i. Find wire extension with white triangular head with black, yellow & green wires at opposite end ii. Connect black off extension to black wire coming off ballast iii. Connect Yellow / Green wire to red wire coming off ballast iv. Connect triangular head to corresponding plug on Teryx Factory Wiring End

Kawasaki Teryx Electric Steering Installation Manual


Filed Under (Kawasaki) by admin on 29-04-2012

installation Instructions for Kawasaki Teryx 1. Before installation, center steering wheel and verify tires are straight. 2. Begin by removing all Phillips screws retaining the plastic hood to the front grill, headlights, and frame structure and remove front clip assembly. 3. Remove plastic shroud by removing the 4 phillips screws that retain it to the frame. 4. There are 2 bolts that hold the steering column tube in place and you need to reach up under frame work to get to them. They are 14 mm and you need a box and open end wrench to access them. Loosen the upper one and remove the lower one. Remove the pinch bolt at the column shaft and u-joint. Remove the lower pinch bolt at the rack and u-joint and while tilting the column up and down remove the stock steering shaft.
5. Once the shaft is removed, you are ready for installation. Your bracket and motor has come completely assembled as shown below. You will need to remove the lower shaft from the motor to install it. After removal of the shaft you will need to loosen the 3 mounting bolts from the bracket to the motor to allow clearance for the bracket to slide over the frame piece where it will mount

Kawasaki Teryx Bowkaddy Installation Instructions


Filed Under (Kawasaki) by admin on 25-10-2010

The most effective method of mounting Bowkaddy on a Kawasaki Teryx is with the use of Kaddy Bracket UTV. However, one small after-market modification is necessary to make the bracket fit the rear roll bars on these side by side vehicles. Two additional 21/64″ holes must be drilled in the bracket at the locations shown in the image below. For more product and installation information,

Kawasaki Teryx 750 Cab Enclosure Kit Installation And Removal Manual


Filed Under (Kawasaki) by admin on 25-10-2010

Remove seats and set aside for better access to vehicle interior. Refer to Owner’s Manual for instructions. ii) Remove lower foot guardrails and set shoulder screws aside for later use. Loosen 19mm bolts ( A in Fig.1) until 3/16″ gap can be achieved. iii) Loosely fasten rubber stops ( B in Fig.1) to Hinge Mounting Brackets using 6mm bolts. Mount brackets to vehicle as shown in Fig.1 and hand tighten 19mm bolts. iv) Align lower bracket hole to existing foot guard mounting hole and fasten with OEM shoulder screw ( C in Fig.1). NOTE : Apply pressure to screwdriver in order catch threads on nuts. v) Adjust upper edge of brackets with mallet to make bracket edge flush to roll bar edge (Fig.2). Tighten 19mm bolts. Adjust and tighten rubber mounts. FLUSH A B Fig.2 Fig.1 2. Rear Bracketery i) Remove 14mm bolts from lower mounting points on rear crossbar. Install Striker Mounting Brackets as shown (Fig.3). Reinstall bolts and hand tighten only . Attach Striker Plates using (4) ¼-20 x 3/8″ screws, keep loose for later adjustment. ii) Remove 14mm bolts from upper crossbar and install Upper Rear Panel Brackets as shown (Fig.4). Tighten 14mm bolts back into place. 3. Panel Installation i) Install low density foam to interior of panels as shown (Fig.5.) Approx. (8) 3″ long strip are required on each side panel. Install low density foam to entire door / panel interface. ii) Mount side panels to roll cage and temporarily clamp to top roll bar. Loosely insert remaining (2) shoulder screws to each foot well. Adjust each panel to obtain proper alignment at front, top and lower rear. iii) Ensure hinge mounting bracket edges are flush with inside door frame and transfer hinge bolt hole locations onto plastic panels. Remove panels and drill holes using ¼” bit. Re-install panels and shoulder screws onto vehicle. iv) Mount hinges as shown (Fig.6) with (8) ¼-20 x 5/8″ Lg. Flat Head screws. DO NOT OVER TIGHTEN

Kawasaki Exhausts – ZX-6 ZX-10 Zx-14 Exhaust – Slip-ons INSTALLATION MANUAL


Filed Under (Kawasaki) by admin on 25-10-2010

Our favorite exhaust options for Kawasaki ZX Ninjas – ZX-10,ZX-6r, and the new horsepower king, Zx-14.. Grab your horsepower today. We love Rob Muzzy and Muzzy Exhausts.Going back to Doug Chandler and Scott Russell, Muzzy has been synonomous with Kawasaki and performance – and for years, if you rode Kawasaki,and you were on the podium, Muzzy was on your exhaust. We also feature Arrow and Yoshimura exhausts for your ZX-6R, ZX-10 and ZX-14. We love the sound of a Yosh exhaust on any Kawasaki Ninja. Yoshimura Oval (RS-3) Race Slip-On for Kawasaki ZX14R 2006 The easiest and least expensive way to experience Yoshimura performance is with our Slip-On/Bolt-On lines. Bolt-On style bolts to the O. E. M. mid-pipe Slip-On style with its stainless steel easily attaches to the mid-pipe RS-1 is available where noted Usually, no jetting or re-programming is required and installation is a snap Hindle Stainless Exhaust High Head Pipes – Kawasaki ZX6R-RR 03-04 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo North Denver News Powered by Joomla! Generated: 19 October, 2010, 12:28 Hindle Stainless Exhaust Low Head Pipes – Kawasaki ZX9R 00-03 The worlds lightest stainless steel exhaust system. Increase horsepower and torque throughout the entire rpm range. Lightweight, strong stainless steel header design looks great and weighs less than stock headers. Available in low- and high-mo

2011 Kawasaki W800 Specifications


Filed Under (Kawasaki) by admin on 17-11-2010


* Engine type Air-cooled, 4-stroke Vertical Twin
* Displacement 773 cm³
* Bore x stroke 77.0 x 83.0 mm
* Compression ratio 8.4:1
* Valve/Induction system SOHC, 8 valves
* Fuel system Fuel injection:?34 mm x 2 with sub-throttles
* Ignition Digital
* Starting Electric
* Lubrication Forced lubrication, wet sump


* Transmission 5-speed, return
* Final Drive Chain
* Primary reduction ratio 2.095 (88/42)
* Gear ratios: 1st 2.353 (40/17)
* Gear ratios: 2nd 1.590 (35/22)
* Gear ratios: 3rd 1.240 (31/25)
* Gear ratios: 4th 1.000 (28/28)
* Gear ratios: 5th 0.851 (23/27)
* Final reduction ratio 2.467 (37/15)
* Clutch Wet multi-disc, manual


* Frame type Double-cradle, high-tensile steel
* Wheel travel, front 130 mm
* Wheel travel, rear 105 mm
* Tyre, front 100/90-19M/C 57H
* Tyre, rear 130/80-18M/C 66H
* Rake/Trail 27° / 108 mm
* Steering angle, left / right 37° / 37°


* Suspension, front 39 mm telescopic fork
* Suspension, rear Twin shocks
* Type: Twin shocks
* Spring preload: 5-way


* Brakes, front Type: Single 300 mm disc
* Caliper: Twin-piston
* Brakes, rear Type: Drum, 160 mm


* Dimensions (L x W x H) 2,180 x 790 x 1,075 mm
* Wheelbase 1,465 mm
* Ground Clearance 125 mm
* Seat height 790 mm
* Curb Mass 216 kg
* Fuel capacity 14 litres