Suzuki DRZ 400E/ S/S M/ Kicker All years and Kawasaki KLX400 All Years CFC Offroad Clutch Cover Installation Instructions

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Filed Under (Tips and Review) by admin on 25-10-2010

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1. Wash engine sidecase to remove any dirt, grease, oil, etc. 2. Clean engine sidecase and the CFC case guard with quick drying solvent such as electrical contact cleaner or brake cleaner 3. Apply an even layer of Permatex 16B silicone adhesive* to the backside of the CFC guard. This can be a messy job and most find the best tool to spread it evenly is your finger. It is suggested that you use a rubber glove to avoid skin contact. Try to get complete coverage free of voids and about 1/16-1/8″ thick 4. Align sidecase Guard with the engine sidecase, keeping the logo horizontal (if the Guard has one). Gently press on the engine sidecase. Once you feel that it is aligned and positioned properly, press with enough evenly distributed pressure to get an equal squeeze out of Permatex all around the perimeter. Don’t worry if you end up with excess. Excess adhesive can be cleaned up with a rag and mineral spirits or brake/contact cleaner. Let dry overnight 5. A couple of strips of masking tape can be carefully applied to assure the guard doesn’t move

Kawasaki V-Force 700 Snorkel REMOVAL AND INSTALLATION

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

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Remove plastic from around air filter housing. Remove clamp attaching stock intake (snorkel) from air box. Loosen upper radiator hose clamp. Rotate it so the drive is on the opposite side of the new snorkel and retighten it. Loosen metal support for front plastic. Have a friend gently pull outward and carefully install the new snorkel. Position snorkel so it does not interfere with any cables or steering stem. Move handle bars back and forth. Check for clearance around new snorkel. Make sure all wires, cables and steering stem do not come into contact with the snorkel. Adjust as necessary. Tighten clamp at the air box. Reinstall plastic in opposite order of removal. At your own risk, you can cut slices in the black plastic hood on front of the quad to force the maximum amount of cold fresh air and produce additional horsepower. Jetting will vary from quad to quad and with the altitude

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KAWASAKI TERYX POWERFLOW INSTALLATION PROCEDURE

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

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1. Remove the airbox and clean thoroughly. 2. Cut off the factory plastic ring on airbox. DO NOT cut a bigger than 3″ 5/8 diameter (See figure #1) 3. After cutting hole in airbox place billet adapter inside the airbox and insert hole then mark the mounting holes for the billet adapter. 4. Drill the marked locations with a 7/32 drill bit. 2. Install the billet adapter from the inside of the airbox with the Trinity Racing logo at the top of the airbox. Insert the bolts and washers from the carburetor side of the airbox and then secure it with blue loctite then tighten bolts. 3. Install Outerwear over new filter. 5. Install the filter onto the billet adapter and make sure the rubber neck of the air filter is completely free of oil. Tighten the filter clamp securely, but do not over tighten and cut into the rubber neck of the filter. 6. Reinstall the air box assemble with lid ( if you choose to reinstall the airbox lid ) onto the vehicle. Be sure to tighten and double-check all the nuts and bolts you have installed. 7. Check your vehicles jetting. Depending on your modifications and riding altitude, a jetting change may be required for your ATV to run properly.

Kawasaki Winch Mount Installation Manual

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

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1. You will need to remove the lower Front Moulding of the ATV for installation of the Winch Kit. 2. Position the Winch with the motor on the LEFT side in the mounting location and slide the Winch Mount Plate in under the winch. Attach the Winch Mount Plate to the frame with the U-bolts and Nylock Nuts provided. Tighten at this time. See Picture Winch Mount Plate 3. Install the Roller Hawse Bracket to the Lower Winch Plate and to the front bars (behind the bars) of the ATV using the U-bolts, Carriage Bolts and Nylock Nuts. See Picture Below. Winch Mount Plate Roller Hawse Bracket 4 4. After winch installation is complete, reinstall lower Front Moulding of ATV. Remove one of the long rollers and the two side rollers and feed the winch cable through the roller hawse. Reinstall the rollers and be sure rollers move freely. Attach the Roller Hawse to the Roller Hawse Mount Plate using the 3/8″ x 1″ Bolts and Nylock Nuts provided with the winch. Tighten all hardware

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Kawasaki Spacers Installation Manual

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

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1. Remove the tops of both risers and move the handlebars out of the way. Caution: Try not to turn your handlebars upside down. Air from the Brake/clutch reservoir may get into your line causing front brake/clutch problems. Put a towel or blanket on your bike to protect it. 2. Remove the two nuts that hold the risers on and remove the stock bolts from the risers. 3. Refer to fig 1. Install the new bolts through the risers, through Jim’s Spacers and through the triple tree. 4. Install the washers with locknuts and but don’t tighten them all the way. 5. Install the handlebars in the risers and install the top part of the risers. 6. Tighten the locknuts up insuring the handlebars are straight. 7. Double check that all fasteners are tight

KAWASAKI Z1000 GTR Electronic Cruise Control Installation Manual

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

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The actuator spool is installed in the CIU housing with the actuator cable. The actuator spool is rotated to fully extend the cable. 2nd step. The dual spool and carburettor cable are installed. The carburettor cable is attached to the lower groove in the dual spool. The other end of the carburettor cable is attached to the carburettors. Note the position of the roll pin. It is nearly contacting the end of the groove in the actuator spool. The free play in the carburettor cable must be adjusted so that the cable outer can be pulled out 2 ~ 3mm before the carburettors start to open. This ensures that the cruise control cannot prevent the carburettors returning to idle. If more free play is allowed the response of the cruise control is compromised. This adjustment of free play is usually performed after final assembly of the CIU is completed and the CIU is in its final location. This is because flexing the cable affects the free play. It is shown at this stage in these diagrams to improve clarity. After this adjustment is performed, the carburettor cable adjustment MUST NOT BE MOVED. All future adjustments of free play in the throttle must be performed on the throttle cable from the throttle grip. If incorrect free play in the carburettor cable is suspected due to inconsistent cruise operation or because of inconsistent idle speed, the adjusters on the throttle cable from the hand grip must be backed all the way off to give as much free play as possible. If this does not result in AT LEAST 5mm of free play in the throttle cable, the throttle cable must be removed from the hand grip or CIU before adjustment of the carburettor cable is attempted. This is crucial because the amount of free play in the throttle cable also affects the apparent free play in the carburettor cable

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Kawasaki Bar Riser Kit Installation and removal Instructions

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

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our handlebars back to the current position. Witha 19mmwrench, loosen the bar clamp locknuts on the bottom side of the upper triple clamp. (Figure 1) Witha 10mmsocket, remove the 4 bolts that hold on the upper handlebar clamps as shown in (Figure 2) Lift the handlebars up and out of the lower bar cradle/clamps. You can strap or zip-tie them out of the way for now. Remove the bar clamp locknuts and washers that you loosened instep 2. Pull the lower handlebar clamps up and out of the triple clamp. (Figure 3) Remove the rubber sleeve and washer from the original lower handlebar clamps. (Figure 4) Insert the rubber sleeves and washers into the upper triple clamp. (Figure 5) Insert the new handlebar clamps in the upper triple clamp. The bolts will go through the rubber sleeve and washer as shown. (Figure 6) Install a rubber sleeve and washer on the bottom side of each handlebar clamp bolt. Thread the lock nuts onto the handlebar clamp bolt. (Figure 7) Do not tighten yet. Re-install handlebars in lower bar cradle/clamps. Make sure they are in the same position that you marked in step 1. Install upper handlebar clamps. Tighten mounting bolts to motorcycle manufacturer’sspecifiedtorque. Now torque down the locknuts you installed instep 9. Tighten the locknuts to the motocycle manufacturer’sspecifiedtorque.

Kawasaki Ultra/ STX-R Billet Head Installation Instructions

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

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1) Remove stock head and clean the top surface of the cylinder. 2) Remove the stock water fittings from the stock head and install them in the ADA head in the same order. 3) Install all o’rings in the ADA billet head, use small amounts of grease to hold them in place, do not use super glue or silicone. 4) Apply a small amount of grease to the small (OR020) o’ring at the top of the dome. This will allow the dome to easily slip into the head shell. Be careful when turning the head upside down to install onto the cylinder, as the domes can slide out of the head shell. 5) Make sure all the o’rings are in place and place the head on top of the cylinder with the water outlets on the top side. You must be sure that none of the o’rings slip out of their groove, as this will cause an o’ring to get pinched and a water or compression leak could result. 6) Use the additional 8mm flat washers on the taller studs, along with the stock wash- ers. 7) Torque all of the nuts to 15ft/lbs, in a center-out criss-cross pattern. Now, torque them again to 18ft/lbs. 8) After the 1st time out riding the head should be re-torqued

KAWASAKI 400 PRAIRIE ATV WINCH MOUNT INSTALLATION ISTRUCTIONS

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

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1. Place the mounting plate into position on the front bumper tube assembly and attach with the four ¼- 20 u-bolts, hex nuts, and lock washers. See the illustration below for detail. 2. Place winch onto the mounting plate and attach with the four 5/16-18 hex bolts and lock washers that came with the winch. See the illustration below for detail. NOTE: There are two sets of mounting holes to accommodate the 3.0ci winch, A2000 and A2500 winches. 3. Tighten all fastners securly at this time. Place the vinyl caps on the ends of the ¼-20 u-bolts, to cover up the sharp edges of the u-bolts that are exposed. 4. Make all electrical connections. Use the winch manuel that came with the winch for instructions to make all electrical connections

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Kawasaki ZZR600 Scottoiler Installation Manual

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

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Locate the vacuum – There is a rubber bung over a spigot on the inlet side of each carburetor. Remove one of these bungs and then press the Damper Elbow, part number 4, onto the spigot. Later models: These spigots might have vacuum pipes between them, in which case cut into the pipe and insert the T-Piece from the Scottoiler kit. Then press the Damper Elbow onto the third leg of the tee. The RMV can be mounted under the seat or behind the number plate. The more vertical the RMV the better and remember to avoid exhaust and engine components. For further information, see our easy step installation guide – ‘RMV Positions, General’ . The Dispenser Assembly, shown left , is routed along the underside of the Swingarm using Dispenser Mounting Sleeves, Cable Ties & Glue. Note: an epoxy resin (eg. Araldite) is req’d to bond the sleeves to the Swingarm. For further information see our easy step installation guide – ‘Dispenser Assemblies, General’ . The nib should feed the sprocket between the 6 & 7 o’clock positions, with the cut face facing outwards, as shown bottom left. Note: This is a generic image Once fitted, fill and prime the system and set the adjuster knob to ‘prime’. Start the engine and turn the adjuster knob until a flow of between 1 and 2 drops per minute is achieved. Check the condition of your chain after a ride, and then adjust as required.