Assembly Instructions
Contents
1. Kawasaki Assembly Instructions KLZ1000B Helmet Lock 99994 0491 Before you begin read through these instructions and check that all parts are present Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect installation Kawasaki recommends that all genuine accessories should be fitted by an authorized Kawasaki dealer The following symbols indicate the information for proper installation and operation in this instruction Indicates a procedural step or work to be done O Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Refer to the Service Manual P No 99924 1478 01 for detailed procedures Parts List Qty 92161 1721 11056 4251 92172 0835 92153 1948 Bracket 39184 0040 5 106C635 P 2014 Kawasaki Heavy Industries Ltd Page 1 of 5 Installation Instructions Assembly Procedure One Key System O Using a combination of tumblers allows the lock rotor to be assembled to fit the existing ignition key O The four kinds of tumblers are a different length A to each other as shown Tumbler 1 2 5 mm 0 098 in Tumbler 2 3 0 mm 0 12 in Tumbler 3 3 5 mm 0 14 in Tumbler 4 4 0 mm 0 16 in O The tumblers are separated into 4 plastic bags of different colors Keep them in the bags until needed to prevent them being mixed up Step 1 Install2. 5 springs A and 5 tumblers 1 B from one bag to the grooves C of the rotor D Press each tumbler into its groove until it fully seats NOTE O The projection of the tumbler should sit over the spring 106370CS1 C Step 2 Lightly hold the tumblers A in the rotor B and insert the ignition key C NOTE O If the tumblers are not held in place the tumblers or springs may become dislodged 106371 6S1 C Page 2 of 5 Step 3 f the tumbler A is the correct one for the cut in the key it will sit level with the rotor B once the ignition key C is inserted Incorrect D Projecting high upper or lower of rotor Incorrect E Projecting low upper or lower of rotor Correct F Level with the rotor f any of the tumblers project out of the rotor go to Step 4 f all tumblers sit flush with the rotor it is correct Go to Step 5 While lightly holding the tumblers in the rotor remove the ignition key NOTE O If the tumblers are not held in place the tumblers or springs may become dislodged Replace any projecting tumbler s with tumbler s from another bag and repeat steps 2 3 and 4 again until all tumblers are level with the rotor Step 5 Insert the key again as described in Step 2 and make sure that all the tumblers A are level with the rotor The stopper tumbler B should be projecting as shown Ignition Key C NOTE Do not attempt to install the rotor into the
3. Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads reads Gia im i 3 4 4 9 0 35 0 50 30 43 in lb 5 9 7 8 0 60 0 80 52 69 in lb 14 19 1 4 1 9 10 13 5 25 34 2 6 3 5 19 25 44 61 4 5 6 2 33 45 73 98 7 4 10 0 54 72 115 155 11 5 16 0 83 115 17 0 23 0 125 165 165 240 165 225 225 325 23 0 33 0 Check tightness of all fasteners in regular interval Retighten loose fasteners P No 99958 0004 Page 5 of 5
4. helmet lock if the tumblers are not level If the tumblers are not level the lock may become stuck when fitted to the helmet lock 106372 CS1 C Step 6 Pull out the ignition key a little from the rotor A to insert the rotor into the helmet lock B Install the rotor to the helmet lock Align the stopper tumbler C at the edge D of helmet lock While gently pushing turn the key clockwise Page 3 of 5 Align the tumblers A and groove B of helmet lock Carefully press the rotor down You will hear a click when it is fully seated Remove the ignition key After installing the rotor make sure that the lock operates correctly and when removing the ignition key the rotor is secure in the helmet lock 106C637 P Assembly Procedure Helmet Lock Remove the seat Refer to the Service Manual Install the bracket 4 temporarily O Fit the projection A of the bracket 4 to the hole B of the frame Install the damper 2 O Align the edge A of the damper 2 with the lower position of the bracket 4 Install the bracket 3 and bolt 6 temporarily Install the helmet lock 1 O Fit the projection A of the helmet lock to the hole B of bracket 3 4 SI06C641 P Page 4 of 5 Tighten the screw 5 and bolt 6 securely Basic Torque for General Fasteners The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts
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