LSL ZGT40A Installationsanleitung

Fitting Instruction

Article-No. : 120K130

Product : Super Bike Conversion Kit

Model : Kawasaki GTR 1400 2008Æ

Type : ZGT40A

Important:

Read this instruction manual carefully and mind all warnings and tips. You should do this work

only if you‘re qualified; otherwise we recommend this mounting to be done by a professional

workshop. Improperly mounting of this kit can reduce the driveability of the motorcycle and may

be a risk to your health and life.

Special works are marked with the following signs. Please take special care on these works.

Warning! Important mounting instruction. It shows risks to your life and health.

LTips for mounting and maintenance or to avoid damage.

Fitting:

Mounted conversion kit

LThe battery ground should be disconnected before working on electric wiring and switches!

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Rev. 00 08/04/2009 Page 1 of 4

Remove brake-hose(s). Caution: avoid brake fluid on painted surfaces! Any work on the

brake system or bleeding the system should be done by an authorized dealer or a

d mechanic!qualifie

Remove handlebar controls, clutch lever bracket and brake cylinder assy, then remove the

original handlebar. Loosen the clutch hose’s fixation at the top yoke

Mounting the adapter is done in

several steps:

1. Mount clamping devices (A)

loosely on the adapter plate

(B). Fit handle bar into the

clamping devices (A) and

tighten them with nickel-

plated M8x25 slightly so the

clamps can align to the

handle bar. Now tighten the

bolts from underneath the

plate with 25Nm / 18.44lbf ft

torque. Demount handle bar

at last.

2. Fix adapter brackets (C) on

the top yoke with M8x30 and

tighten them with 25Nm /

18.44lbf ft torque.

3. Fit pre-mounted adapter

(A&B) with nickel-plated

M8x25 and M8x45 on the

adapter brackets (C). Tighten

them with 25Nm / 18.44lbf ft

torque also.

LRecommended handlebar type: LSL-Fat Bar, high / Type XB3

Mount new handle bar into the clamps and adjust it. If the upper clamp is marked, the mark faces

forward. Tighten the handlebar clamps evenly with 25Nm / 18.44lbf ft torque.

Remount all handle bar controls and adjust them. Remember to check clearance between fairing

and handlebar and re-adjust handle bar, if necessary. Now you can drill bores to fix the handlebar

controls, if using a LSL-handlebar. Mount the left grip with suitable glue.

LIt was necessary to reduce the glove boxes opening angle to reach an ergonomic seating.

Take care to avoid damage to the glove boxes cover.

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Rev. 00 08/04/2009 Page 2 of 4

Instructions for rerouting cables hoses and wiring harness:

Throttle cable: Routed as original. Check throttle cable for free movement on every steering

angle.

Brake hose: Mount attached brake hose

with new seal rings. Mind the mounting

instructions that are delivered with the brake

hose. Route as shown and fix it with

rubberized clamp and zinc-plated bolt

M6x12 at the bracket.

Clutch hose: The laying needs no change, but the

fixation at the top yoke needs to be moved upward. Fit

new bracket with nickel-plated bolt M6x12 on the top

yoke; then fix clutch hose with original bolt, attached

washer and self-locking nut M6 at the bracket.

Wiring harness: No changes, routed as original.

Make sure that no cable, hose or harness is

bended and stays tension-free over the whole

steering angle.

The conversion kit is now completely mounted. Always check local laws and your manufacturer’s

warranty conditions for using aftermarket parts on your bike!

Ride safe and have fun!

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Rev. 00 08/04/2009 Page 3 of 4

LSL-Motorradtechnik GmbH • D-47809 Krefeld

www.lsl.eu

———————————————— Accessories from — The Original ——

Rev. 00 08/04/2009 Page 4 of 4

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