Baron Air & Fuel_BIG AIR KIT -- PINSTRIPE, CHROME Kawasaki Vulcan 900 - Manual

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BIG AIR KIT - Kawasaki Vulcan 900 (All Models)
CAUTION! We Strongly recommend that a qualified technician install this kit
if you do not completely understand the instructions prior to the install.
Revision: 2.6 - 04/02/2010
Install Time: 60 Minutes
INCLUDED IN THE KIT:
(1) Billet BAK Cover
(1) Re-usable Performance Air Filter
(1) Black BAK Backing Plate
(1) M5x10mm Button Head Screw
(2) 1/4" Lock Washers
(1) 1/2" ID Rubber Hose (18 1/2" length)
(1) BAK Filter Raincoat
(2) 1/4-28 x 1 13/16" Zinc Hex Bolts
(2) Aluminum Spacers
(1) Nylon Nipple Pre-installed
TOOLS REQUIRED:
3, 4 & 5 mm Allen Wrenches
Blue Loctite®
Pliers (Std. & Needle-nose)
10 & 12mm Sockets
Phillips & Flat Screwdrivers
Factory Kawasaki Service Manual
INSTRUCTIONS:
Please read all directions before starting this install. If at any time you are unsure or do not understand these
procedures, please call us at the shop, or email [email protected] for help. Although it is not required,
the BAK may be easier to install after removing the fuel tank. Please make sure the vehicle is cool before
starting your work.
1. Using a 4mm allen wrench, remove the 4 cap-head screws that hold the stock chrome air box cover on.
2. Using a phillips screwdriver, remove the screw at the top center of the air box. This holds the air filter on.
Remove the air filter and plastic housing.
3. With a 5mm allen wrench, remove the 5 cap-head screws that hold the air box to the throttle body.
4. Remove the 2 bolts that were under the stock air filter with a 5mm allen wrench.
5. Remove the idle-speed adjuster from the air box, unplug the inlet temperature sensor, and remove the upper
& lower vent tubes.
6. Remove the philips screw holding the sensor onto the stock air box. Install the sensor into BAK backing plate
with the button head screw provided and the stock o-ring.
7. Remove the vent hose that leads to the air switching valve. Replace this hose with the 18-1/2" long hose
provided. Be sure to run this hose behind the throttle body so it can be inserted onto the nipple on the BAK
backing plate. A little WD-40® or thin grease on this fitting will help installing the hose provided.
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.
© 2013 Barons Custom Accessories
5221 Oceanus Drive Huntington Beach, CA 92649 (925)583-2499 - Ph. (714)901-0520 - Fax www.baronscustom.com [email protected]