Suzuki DRZ 400E & Kawasaki KLX400E Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 13-02-2012

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1. Remove the seat, side panels, and fuel tank. Kill switch connector Photo 1 2. Unplug and remove the stock headlight. 3. Unplug and remove the stock kill button. See Photo 1. 4. Unplug and remove the stock taillight. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. 5. Taillight Installation: Attach the provided LED taillight to the under side of the rear fender using the provided countersunk mounting hardware as shown in Photo 2. Route the taillight wires forward to the area on top of the airbox along the right side of the fender. Secure the taillight wires to the taillight plastic with zip-ties so the tire cannot make contact. Photo 2 6. Rear Turn Signal Installation: Attach the rear turn signals to the flat portions on the sides of the LED taillight. Position them so they are out of the path of the exhaust. Route the wires forward securing with zip-ties. Route the right turn signal wires and the taillight wires around the front of the muffler mount and between the fender and the black plastic splashguard as shown in Photo 3. Route Right Turn Signal & Taillight wires here Photo 3 Page 3 of 10
7. Brake Light Switch Installation: This step requires bleeding the rear brake. If you do not feel comfortable performing this step please refer it to a qualified mechanic. Installation: Remove the guard that protects the rear master cylinder and reservoir. Temporarily remove the bolt that secures the brake reservoir to the frame. Remove the bolt that holds the banjo fitting to the top of the rear master cylinder. Replace this bolt with the provided hydraulic switch retaining the upper and lower crush washers as shown in Photo 4. Bleeding the Brakes: Do not begin this process without a fresh bottle of brake fluid. Remove the lid from the brake fluid reservoir. Put the box end of 8mm wrench over the brake bleed nipple and install the bleed hose (supplied) tightly over the nipple. Position the loop on the hose above the nipple as shown in Photo 5 with the other end of the hose in a container to catch the fluid. Crack the bleed nipple open about 1/8 to a quarter turn keeping the loop in the hose vertical. Slowly depress the brake pedal to fill the hose with fluid. Pump slowly until you have brake fluid extending up into the loop, then you can pump the pedal fairly aggressively to drive air out of the system – The fluid above the bleed nipple will prevent air from re-entering the system. DO NOT LET THE RESERVOIR GO DRY – ADD FLUID AS NEEDED. Pump the pedal until there are no more bubbles, and then close the nipple with the wrench. Double check that the pedal is firm and the brake works properly.

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Suzuki DRZ 400K Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 11-02-2012

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DRZ 400 (Kick Start) Dual Sport Kit Installation Manual 1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the side panels, seat, and gas tank. 3. Unplug the headlight from the stock wiring and remove. 4. Unplug the kill button from the stock wiring and remove (Photo 2). The connector is a gray two-conductor connector located under the fuel tank. Release detent on connector to separate. Kill switch connector Photo 2 5. Unplug the stock taillight and remove. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. ΒΌ” Photo 3 Countersunk screw and bezel, 4 Places 6. Taillight Installation Position the taillight assembly so that the edge of the red taillight extends past the edge of the fender about 1/4″ as shown in Photo 3. With the taillight positioned as shown Photos 3 & 4 , transfer the four mounting hole locations into the bottom of the fender. Drill the mounting holes at 1/4″ diameter. Use the 6 x 16 mm counter-sunk fasteners and bezels for mounting the taillight

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2007 KTM EXC LED Taillight and Turn Signal Kit Installation Instructions

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Filed Under (KTM) by admin on 31-01-2012

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Remove the seat & fuel tank. Photo 1 Unplug 2. Unplug the two three-pin connectors that mate the taillight & turn signal power leads to the stock wiring harness on top of the airbox. See Photo 1. 3. Unbolt and remove the stock taillight & rear turn signal assembly from the rear fender. The wires & connectors will pull through the gap in the fender/airbox plastic with a little finesse. 4. Unplug the two small white plastic connectors near the upper edge of the stock taillight lens and separate the wire extension from the taillight. See Photo 2. Photo 2 Unplug these two connectors and remove wire extension Photo 3 Remove 5. Using a sharp blade or cut-off wheel, remove the two molded mounting bosses on the bottom of the fender. See Photo 3. 6. Attach the new LED taillight to the fender as shown using the provided countersunk mounting hardware. Use the two longer bolts for the front mounts. The LED cluster should not protrude beyond the edge of the fender

Suzuki DRZ400E Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 23-11-2010

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1. Remove the seat, side panels, and fuel tank. Kill switch connector Photo 1 2. Unplug and remove the stock headlight. 3. Unplug and remove the stock kill button. See Photo 1. 4. Unplug and remove the stock taillight. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. 5. Taillight Installation: Attach the provided LED taillight to the under side of the rear fender using the provided countersunk mounting hardware as shown in Photo 2. Route the taillight wires forward to the area on top of the airbox along the right side of the fender. Secure the taillight wires to the taillight plastic with zip-ties so the tire cannot make contact. Photo 2 6. Rear Turn Signal Installation: Attach the rear turn signals to the flat portions on the sides of the LED taillight. Position them so they are out of the path of the exhaust. Route the wires forward securing with zip-ties. Route the right turn signal wires and the taillight wires around the front of the muffler mount and between the fender and the black plastic splashguard as shown in Photo 3.

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