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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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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 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 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 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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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)

Kawasaki Vulcan Front Suspension Lowering Kit Installation manual

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Filed Under (Kawasaki) by admin on 27-02-2011

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INSTALLATION 1. This lowering method requires replacement of the front spring spacers. This is a simple task, and is completely reversible. First, raise the front tire off of the ground before you begin. Raise the motorcycle so no weight is applied to the front wheel. 2. Cover the gas tank with a thick towel to prevent scratching. Don’t omit this…you’ll be sorry if you do! 3. If the handlebar risers are OEM (stock), loosen the handlebars in their clamps and lift them from the risers, carefully placing them on the gas tank on a thick towel to prevent scratching. This will allow room for the spring spacers to be removed from the front forks. 4. Using a small knife blade, sharp screw driver, etc. in the pinch grove on each side of the triple clamp, gently pry upwards and pop the chromed plastic covers off. These are the covers on the top of the front forks, covering the spring retainers. Below these chrome caps, you’ll find a gold anodized metal plug with a small counter bore in the center. This is the part used to retain the springs within the front fork tubes. Using an extension bar, large Phillips screwdriver, etc., press down a bit in the counter bored area of the plug to take the pressure off of the small internal “C” ring. While this “gold” colored plug is depressed, remove the internal C-ring. The C-ring is made of small diameter wire. Once the C-ring is removed, slowly release the pressure on the plug and it’ll push itself out of the top of the shock. The picture below is of the upper fork leg with the gold retaining plug removed. 5. Stick a finger into the fork tube, and slide the OEM tubular spacer up and out of the fork tube. 6. The picture below illustrates the use of a Scootworks lowering spacer with the fork spring. On the right hand end of the you’ll see a Scootworks lowering spacer. The fork spring stays in the front fork, and you’ll drop in the spacer with the desired amount of lowering. The approximate amount of lowering is marked on each Scootworks spacer. 7. Select the spacers for the desired amount of lowering. The longest spacers supplied are marked as [1] and will lower the front suspension 1″. The spacers of middle length are marked as [2] and will lower the front suspension by 2″. The shortest spacers supplied in the kit are marked as [3] and will lower the front suspension by 3″. Omission of the spacers completely will lower the front suspension by approximately 4″. 8. Install the selected spacers in the fork tubes, on top of the internal fork spring. Place the gold anodized metal plugs on top of the spacers and press them back into the fork tube. Be sure to turn the metal plug so the side with the counter bore is facing outwards. Reinstall the C-rings, and gently lower the front end back to the ground. Make sure the C-rings seat themselves in their respective grooves when the weight of the bike is placed back on the front end. Re-install the chrome caps.

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KAWASAKI VULCAN 800 STRAIGHT SHOT EXHAUST SYSTEM INSTALATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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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 a chrome header flange onto the front and rear head pipes. 3. Install the heat shield to the front head pipe using the two 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. 4. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time. 5. Install the rear head pipe, with the heat shield attached, to the rear cylinder using the stock nuts. Leave them loose at this time. 6. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 7. Slide one dog bone shaped nut plate under the bracket that is welded to each muffler. 8. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. Install a 5/16″ x 1 1/4″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Do this to each muffler but leave the clamp loose at this time. 9. Install one muffler to the four hole bracket welded to the V&H mounting bar using the two 5/16″ flange bolts (supplied) and leave them loose. (See figure 1) 10. Slip the muffler and mounting bar assembly onto the front head pipe while aligning the grommet holes in the mounting bar with the holes in the frame.

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KAWASAKI VULCAN 700/750 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Place the bike on the center stand. 2. Remove the three clamps attaching the heat shield to the left hand head pipe and set the heat shield aside. 3. Remove the two heat shield clamps attaching the heat shield to the right hand head pipe and set the heat shield aside. 4. Loosen the pinch clamps where the mufflers slip onto the muffler box (the black box in front of the rear tire). Remove the bolt attaching the mufflers to the footrest. 5. Remove the left and right hand mufflers and set them aside. 6. Remove the right hand foot rest and brake pedal assembly from the frame. 7. Loosen the pinch clamps where the head pipes slip into the muffler box. 8. Remove the two nuts that secure the right head pipe to the cylinder head. Repeat this step on the left head pipe and save the nuts for reuse. 9. Remove the left and right hand head pipes. Remove the header flange from each head pipe and save the two flanges for reuse. Set the head pipes aside. 10. Remove the two bolts (one on each side) that mount the muffler box to the frame. Lower the muffler box down and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Remove the two bolts from the charcoal canister mount, the canister is located in front of the rear tire. Using the two 6mm x 16mm bolts (supplied) install the centerstand stop bracket, (stamped 205), by aligning the holes in the bracket with the holes in the canister mount. Be sure the bend closest to the holes in the bracket angles towards the rear of the motorcycle and the tang is pointed to the left hand side. Tighten the two 6mm bolts at this time. 2. 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. Repeat this step with the rear heat shield. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. Leave them loose at this time. 3. Install a three hole mounting bracket to each muffler as shown in figure 1. Slide one dog bone shaped nut plate under the bracket that is welded to the backside of each muffler. Attach the mounting bracket using two of the 5/16″ flange head bolts (supplied), leave them loose at this time. Note : The muffler bracket stamped #284 is for the right hand muffler, bracket #285 is for the left hand muffler. 4. Install the rear exhaust assembly, with the heat shield attached, to the rear cylinder using the stock flanges and nuts. Install the stock muffler mounting bolts through the rear footrest brackets, the supplied muffler brackets, and finger tighten the nuts. Leave them loose at this time. 5. Repeat step #4 with the front head pipe

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KAWASAKI VULCAN 1500 PRO PIPE HS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the mufflers by loosening the pinch clamps on the front of each muffler. 2. Remove the muffler mounting bolt from the right side passenger footrest, slide the mufflers off and set them aside. Note: Save the mounting bolt, it will be reused for installation. 3. Loosen the pinch clamp on both front and rear head pipes, they’re located at the resonance chamber (the black box where the pipes meet). 4. Remove the two acorn nuts that mount the head pipe to the cylinder head. Remove the two piece header flange and set it aside. 5. Remove the front head pipe by rotating it down and pull it out of the resonance chamber. 6. Remove the two acorn nuts and flange from the rear head pipe. Remove the two bolts from either side of the resonance chamber and lower rear pipe and resonance chamber down and out and set it aside. 7. Remove the rubber grommets at the resonance chamber mounting points. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Install the new mounting bracket (stamped 317) to the inside of the stock muffler mounting point (Refer to FIG. 1). 2. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edge of all three heat shields with the location of the mounting clips that are welded to the backside. Position the front heat shield over the head pipe and feed the tail end of the hose clamps into the clips. Be sure that each hose clamp is engaged with both clips. Repeat this step with the rear and collector heat shields. To facilitate the installation of the collector heat shield use a forward sliding motion from the rear of the collector. Do not force the collector heat shield directly onto the collector as damage to the heat shield will result. Note: the collector heat shield uses the 3/8″ wide clamps. 3. Rotate the hose clamps in the shields so that the screw drives are accessible. Tighten only finger tight at this time. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Check to be sure that the stock exhaust gaskets are in good shape. If you have any doubts as to their condition, replace them. 5. Install the header with the heat shields attached, to the front and rear cylinders using the stock nuts and bolts. Leave them loose at this time. 6. Slide the chrome muffler clamp (supplied) onto the inlet end of the megaphone. Install the 5/16″ x 1 1/4″ bolt with a flat washer on either side of the clamp followed by the 5/16″ lock nut (hardware supplied). Leave the clamp loose at this time. 7. Slip the megaphone onto the head pipe collector, engaging the collector heat shield between the clamp and the outer slip joint tube. Slide one dog bone shaped nut plate under the bracket that

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