Baron Air & Fuel_BIG AIR KIT SMOOTH Kawasaki Vulcan 2000 - Manual

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BIG AIR KIT (BAK) - Kawasaki Vulcan 2000
CAUTION! We strongly recommend that a qualified technician install this kit
if you do not completely understand the instructions prior to the install. Have
the air/fuel mixture analyzed after installing this kit.
Revision: 2.8 - 04/02/2010
INCLUDED IN THE KIT:
(1) Decorative BAK Cover
(1) Re-usable Performance Air Filter
(2) 1/4-28 x 1 13/16" Hex Bolts
(2) 1/4" Lock Washers
(2) 3/8"x 1.25" Aluminum Spacers
(1) Air Sensor Receiver Tube Pre-installed
(1) Rubber Washer Pre-installed
(1) E-clip Pre-installed
(1) O-Ring Pre-installed
(5) M6-1.0x16mm Flathead Screws
(1) Black BAK Backing Plate
(1) BAK Filter Raincoat
(2) 1/2" Rubber Caps
(2) 18 ga x 4" Wire Black
(2) Butt connectors
(1) Nylon Barbed Nipple (Pre-installed)
TOOLS REQUIRED:
3, 4 & 5 mm Allen Wrenches
10mm Open-End Wrench
Pliers (Std. & Needle-nose)
10 & 12mm Sockets
Phillips & Flat Screwdrivers
Factory Service Manual
INSTRUCTIONS:
NOTE: We recommend the use of blue Loctite® on all fasteners and mounting hardware.
1. Remove fuel tank per Kawasaki service manual instructions. Please make note of the vent and drain hoses
connection points for later reconnection.
2. Remove stock air filter cover (4 screws), the stock air filter (1 screw) and then stock air box.
3. Unplug the air sensor and then disconnect the two hoses from back of air box.
4. Remove hoses going to top of each cylinder cover and cap off with supplied rubber plugs/caps, use the stock
clamps to lock in place.(You may shorten the plugs/caps if you like) It may be necessary to squeeze the clamps
closed slightly to get a good seal.
5. Remove the vent hoses that run to the black control valve, leave the control valve plugged to avoid FI error
lights on the dash.
6. Remove air sensor and rubber grommet from stock air box.
7. Install air sensor receiver tube in through the rear of the backing plate, place the rubber washer over the
portion of the tube that protrudes through the backing plate and insert the E-clip in the grove of the tube to
lock it in place. Insert the o-ring into the groove inside the tube. Insert/press the stock air sensor into the tube
from the rear of the backing plate. Make sure the sensor is seated & snug.
Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or
fitment may be required. Barons bears no responsibility on installation costs associated with this product.
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5221 Oceanus Drive Huntington Beach, CA 92649 (925)583-2499 - Ph. (714)901-0520 - Fax www.baronscustom.com [email protected]