Kawasaki KZ750 Twin Carburetor Installation Manual

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

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The first Kawasaki KZ750 twin was built in 1975 and sold as a 1976 model as a KZ750B1. For the first four years of production (1976-79), the KZ750B1 through B4 shared identical Mikuni BS38 carburetor assemblies. These assemblies are probably the heaviest twin-carb assemblies ever built and have a couple unique features. The biggest oddity is that the Kawasaki version of the BS38 uses a system where both the pilot jet and main jet are screwed into the float bowl. A good bowl gasket is critical because gas is drawn from the jets into the internal passages that lead to the venturi via channels beneath the gasket inside the float chamber. The pilot jets used are standard BS series fare in that they are Mikuni BS30/96 type but the main jets are unique to Kawasaki BS38 carburetor assemblies. They look like very small air jets and are frequently stripped as they require the correct sized small screwdriver to remove

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Kawasaki Mule 610 Without coil springs Installation

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

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1.)Begin by loosening the lug nuts on both front tires. Raise the unit, using a suitable lifting device or procedure, until the front tires are off the ground. If using a floor jack with stands, chock the rear wheels to prevent the unit from rolling. If using jack stands, make sure the stands are placed under the frame and not the body. Make sure the unit is stable and secure . 2.)Remove the tires / wheels. NOTE: Now is a good time to check the threads on the lug studs. Check for rust, pulled threads or other deterioration that could cause a stud/thread failure. 3.) The first thing to do is remove the front cowl and trunk on the bike. You can accomplish this by removing all the bolts (screws) around the perimeter of the cowl and removing some plastic “snap rivets”. To remove the rivets simply pull the center section up and then the rest will follow. 4.)Place a floor jack, or other suitable device, beneath the left side lower control arm. This is to prevent damage to the tie rod or slip yoke boot while disassembling the lower control arm and strut. Using a 14mm socket, remove the two retaining nuts and lock washers on the top of the struts. 5.)Leaning the strut forward toward the headlamp buckets will put the strut in position to allow you to reach over the top and place the strut spacer in place. Install the strut spacer on top of the coil retainer and tightening the nuts. Install the supplied gasket on top of the strut spacer, and re-install the strut assembly

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KAWASAKI ZX-6R/ RR Carbon Fiber /Aluminum Installation Instructions

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

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1 After bike is cool make sure the bike is secured before beginning the installation. 2 Remove the fairing retaining clips and mounting bolt. Remove the stock mid pipe and muffler. 3 Apply a small amount of high temperature silicone (such as Permatex Ultra Black) to the inside of the exhaust inlet. 4 Attach the LOR exhaust canister to the slip-on tube adapter with the spring tabs aligned (make sure your hands are protected with a pair of gloves in case the tubes slip). You may have to squeeze the mid-pipe adapter tube to fit into the exhaust inlet as the mandrel bends may become slightly out of round due to a cut near the bend (the tube will take form once connected). Slide the canister all the way until the slip-on adapter seats fully against the exhaust inlet. Wipe off any excess silicone. 5 Place each spring over the exhaust side spring tabs and use the spring tool to pull the springs over the adapter spring tabs. Both springs must be secured for proper installation. 6 Apply a small amount of silicone sealer (such as permatex Ultra Black or Ultra Copper) to the inside (inlet side) of the slip-on adapter. Slide the low profile barrel clamp over the LevelOne Adapter pipe. Slide the slip-on adapter pipe over the stock header collector. Do not fully tighten the barrel clamp. 7 Place the round canister clamp with the rubber gasket over the rear of the exhaust and slide to the clamp location. Insert the original stock screw and 8mm washer through the exhaust clamp and finally through the foot peg. Mount the clamp to the outside of the stock muffler bracket. On the opposite side (towards the bike) place the stock 8mm lock washer and stock 8mm nut and start the thread. Do not fully tighten at this time. 8 Standing at the rear of the motorcycle, check the alignment of the muffler. You can adjust/rotate both the exhaust and mid-pipe adapter until the muffler is aligned properly. 9 Once everything is aligned fully tighten the exhaust canister clamp. 10 Fully tighten the low profile barrel clamp over the stock header. 11 Before you start the bike make sure all fingerprints and dirt have been removed from the canister and slip-on adapter. You may use rubbing alcohol to clean the slip-on adapter. After 75-100 miles check all bolts, etc for tightness. It is recommended to apply some light – medium grade thread locker to prohibit any bolts from loosening under the vibration from the bike. 12 Enjoy your LevelOne Racing exhaust system

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