kawasaki vulcan 1600 modification

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KAWASAKI VULCAN 1600 / NOMAD 1600 INSTALLATION INSTRUCTIONS

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

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Remove seat and fuel tank. Consult service manual for proper removal of tank. 2. Remove left side cover and loosen the four bolts inside. Route the two 6-pin connectors between the side cover and frame as shown by the dotted line. Tighten the four bolts. (Fig 1) 3. Route 6-pin connectors under frame and up left side of engine. (Fig 2) 4. Locate the 6-pin connector next to the ignition coil. Disconnect and connect the Fuelpak 6-pin connectors in-line on the stock connector. (Fig 3) 5. Route single black wire to the front of engine and down to the horn. (Fig 4) 6. Disconnect the factory black/white wire from horn. Plug Fuelpak into horn and plug Fuelpak black/white wire to Fuelpak connector. Be sure Fuelpak connector cannot short to frame or radiator. 7. Route black and green wires to battery negative. 8. Attach Fuelpak to Fuelpak harness and mount in left side cover. (Fig 5a 49 State) (Fig 5b Caliornia Models) 9. Before reassembling the bike, make sure handlebar switch is in the engine off position and turn the key on. Fuelpak should light up. Sound the horn. If Fuelpak turns off when the horn is sounded, recheck the black wire connection on the horn and that it is connected to the correct wire from the factory harness. 10. Use supplied zip ties to hold Fuelpak wire harness away from engine. 11. Follow the service manual to reinstall the gas tank

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KAWASAKI VULCAN 1500, 1600, 2000 HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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

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1. Lay a blanket folded several times over the fuel tank to protect it. 2. Loosen (do not remove) from underneath, the two hex nuts holding the risers to the upper triple clamp. (Steering head) 3. Remove the four handlebar clamp bolts. (8mm allen wrench) While sitting on the motorcycle, pull the handlebars and upper clamp off of the risers. They may be slightly stuck and require some force to get free. Lay the handlebar and/or upper clamp/gauge assembly carefully on the blanket. 4. Remove the nuts and risers from the triple clamp. NOTE: Be careful not to scratch the upper triple clamp when installing the new risers. Assemble the supplied lock washers and flat washers onto the supplied bolts. Install the new risers onto the triple clamp and finger-tighten the bolts. 5. Re-install the handlebars and upper clamp/gauge assembly. Tighten the front bolts first closing the gap at the front, and then tighten the rear bolts. Tighten the two riser-mounting bolts securely. Check for adequate clearance and proper routing of cables and hoses.

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Kawasaki Vulcan 1600 Classic Exhaust Installation Instructions

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

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1. Loosen both top and bottom muffler hose clamps as shown. Remove 10mm bolt with 10mm nut on back side of bracket as shown. 3. Loosen 6mm bolt on passenger foot peg bracket as shown. Once loose remove top muffler 10mm nut and 10mm bolt. Slide bolt out of rubber grommet. . Carefully remove top and bottom stock mufflers, by sliding both mufflers out by rear fender. ( Use Phillips screw driver and remove bolt as shown. Remove side cover carefully by pulling towards your body.figure Figure 9 6. Remove rear head pipe by removing two stock socket cap nuts as shown. Once nuts are removed pull rear head pipe away from bike and set aside. (Fig.10)

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Kawasaki Vulcan 1600 Classic Exhaust Serrated Installation Instructions

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

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Loosen both top and bottom muffler hose clamps as shown. (Fig.1&2) Figure 1 Figure 2 2. Remove 10mm bolt with 10mm nut on back side of bracket as shown. (Fig. 3&4) Figure 3 Figure 4 3. Loosen 6mm bolt on passenger foot peg bracket as shown. Once loose remove top muffler 10mm nut and 10mm bolt. Slide bolt out of rubber grommet. (Fig.5&6) Figure 5 Figure 4. Carefully remove top and bottom stock mufflers, by sliding both mufflers out by rear fender. (Fig. 7) Figure 7 5. Use Phillips screw driver and remove bolt as shown. Remove side cover carefully by pulling towards your body. (Fig.8&9) Figure 8 Figure 9 6. Remove rear head pipe by removing two stock socket cap nuts as shown. Once nuts are removed pull rear head pipe away from bike and set aside. (Fig.10) Figure 107. Remove stock front head pipe by removing two stock socket cap nuts as shown. Once nuts are removed pull front head pipe away from the bike and set aside. (Fig.11&12) Figure 11 Figure 12

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

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

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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 Mean Streak 1500 And 1600 BIG SOFT THICK BLANKET Installation Instructions

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

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Place a BIG SOFT THICK BLANKET over your GAS TANK , (LET’S CUT TO THE CHASE, THE MAIN THING IS TO PROTECT THE TANK! ! ! ! ) . 2) You will have to jack up the motorcycle. The best way to accomplish this is with a motorcycle/ATV lift. They are available for a little as $89, and are really an essential tool for maintaining your motorcycle. 3) Remove the stock turn signals completely. They will have to be replaced to do this modification. You may want to install the Kewlmetal turn signal mounts (item #153 or 185) and bullet style signals lights after your fork tubes are in place. 4) Per the Kawasaki service manual, remove the front wheel and be sure to take note of which spacer goes where. Refer to the Service manual for furtherinformation. 5) Remove the front fender Be very careful so you don’t scratch thepaint on the front fender while removing it, the 2 plastic rings holding the front brake lines in place on the front fender will pull out, just make sure to leave them on the lines so they don’t get lost. Now remove the 2 fork guards. 6) Remove the brake calipers and secure the brake pads if necessarywith tape or wire so they don’t fall out. This would be a good time to inspect them for wear, and replace them if necessary. **NOTE** Do not squeeze the front brake lever after you have removed the front wheel. Doing so will cause the calipers to close and then you will have to spread them apart prior to re- assembly. 7) Loosen the bolts on the RIGHT side of the upper and lower tripletree clamps. The fork assembly should drop down. Remove the fork assembly from the bike. 8) Clean the stock fork assembly thoroughly. **NOTE** This kit contains 8 rubber O-rings, (6) Small ones and (2) Fat ones, it is important that these (8) O-rings are placed in the right place for the correct function of the Fat Fork Tubes 9) Slide one of the Small O-rings over the top of the fork assembly until it reaches the bell at the bottom of the shock.

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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 VULCAN 2000 POWERSHOTS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 23-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove right side frame cover. 2. If motorcycle is oxygen sensor equipped, remove passenger seat. Remove two bolts securing operator seat and set seat aside. Locate and unplug oxygen sensor connector from wiring harness (Figure 1).(Note wire routing for reassembly). 3. Remove right side floorboard assembly held in place by two bolts (Figure 2). 4. Remove exhaust port flange nuts. 5. Remove flange bolts securing rear muffler to exhaust system mounting bracket. 6. Remove complete exhaust system. Start by removing front head pipe from exhaust port (assistance may be required). Page 1of 4 K400IN Rev. 1.1 KAWASAKI VULCAN 2000 POWERSHOTS EXHAUST SYSTEM Part #18311 Tools required for installations 6mm Allen wrench 8mm 12mm 14mm sockets 3/8″ Ratchet & Extensions 19mm Wrench 9/16 Wrench Brake bleeder & fluid
7. Check condition of stock exhaust gaskets. Replace if damaged or worn. 8. Remove plastic hose clamp securing rear brake hose to swingarm.Save for re-use. 9. Remove brake hose banjo bolt from rear caliper. 10. Slide hose out of loops in swingarm. 11. Remove three bolts holding stock exhaust mounting bracket and slide bracket off end of brake hose. 12. Slide brake hose through loop on new bracket (stamped 357-P) and install to the original mounting bracket location, using three 8mm x 16mm Allen bolts (supplied) (Figure 3). 13. Check condition of sealing washers on banjo bolt and replace if damaged or worn. 14. Slide brake hose through loops on swingarm and reconnect brake hose to caliper. 15. Reinstall plastic clip onto swingarm. 16. Brake system must be bled or brake will not operate correctly.

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

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

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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 http://northdenvernews.com 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

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K- Drive removable Click & Lock Saddlebag sets for Kawasaki VN 1600 Classic

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Filed Under (Kawasaki) by admin on 05-11-2010

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K-Drive Click & Lock saddlebags are completely reinforced : – Backside : made of a strong hdpi plate; – Upper side, sides and bottom are reinforced with PVC at the inside : – Side flaps are closed with velcro for better protection against the rain. Click & Lock saddlebags have discrete “sliding” grips All buckles, logo & decorative studs are made of “zamack”. A material which is 100% rustfree For maximum protection against the rain, the sideflaps are closed with Velcro

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