Baron Air & Fuel_xXx BIG AIR KIT Vulcan 2000 BLACK - Manual

Page: 1 LA-2372-00
xXx BIG AIR KIT 2004-2009
KAWASAKI VULCAN 2000 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: 1.5 - 07/01/2011
Install Time: 30 Minutes
INCLUDED IN THE KIT:
(1) Black Intake Backplate
(3) Aluminum Stand-Offs
(1) Black Air Filter Covers
(1) Chrome xXx Covers
(1) 1/4-20x1/2" Polished SS Flat Head Allen
(1) 1/2" x 10" Vac Hose
(1) Performance Re-Usable Air Filter
(6) 1/4-20x3/4" Black Flat Head Allen Screws
(5) M6x1-12mm Zinc Button Head Allen Bolt
(1) Chrome Mesh Covers
(2) Black Hose Barbs (one 90 and one straight)
(1) Throttle Body Gasket
TOOLS REQUIRED:
4mm & 5/16" Allen Wrenches
Flat & Phillips Head Screwdrivers
Factory Service Manual
10 & 12mm Sockets
Pliers (Std. & Needle-nose)
Blue Loctite®
INSTRUCTIONS:
1. Remove seat & fuel tank per factory service manual.
2. Remove OEM air cleaner assembly. Remove single Phillips head screw at the top of the filter and remove
the filter element.
3. Remove two 10mm hex bolts that hold the air box to the engine and 5 Allen head bolts holding the airbox
to the throttle body.
4. Remove air box being careful to unplug the manifold temp sensor, ASV (Air Switching Valve) hose and
crankcase vent from the back of the box.
5. Remove ASV hose at the valve. Attach 1/2" x 10" hose (provided) in place of factory hose. Do not cut at
this time.
6. Using three 1/4"-20x3/4" Black Flat Head Allen Screws, install three standoffs onto front side of backing
plate. Loctite® is a good idea at this step. Torque to 8-10 ft. lbs. Note: the allen screws sit into the counter
bore in the back of the backing plate.
7. Remove Manifold temp sensor and rubber grommet from OEM air box. Install both items into xXx
Backplate.
8. Install straight and 90 barbs into backplate. 90 barb should point at approx. 1:00 DO NOT
OVERTIGHTEN.
9. Using five M6x1-12mm Phillips Head Zinc Screws and blue Loctite®, attach backplate to throttle body. Be
sure to use the included gasket and torque to 10 ft. lbs.
10. Plug harness back into manifold temp sensor. Attach vent to small hose barb.
11. Cut the ASV hose to length and attach to 90 barb, making sure it is clear of throttle wheel.
12. Place filter over assembly, and using three 1/4-20x3/4" Black Flat Head Allen Screws, attach black cover to
spacers.
13. With 1/4-20x1/2"polished SS Flat Head Allen, attach mesh and xXx cover to assembly.
14. Re-install fuel tank and seat per Factory Service Manual.
Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or
fitment may be required. LA Choppers bears no responsibility on installation costs associated with this product.
© 2013 LA Choppers
5221 Oceanus Drive Huntington Beach, CA 92649 (925)583-2499 - Ph. (714)901-0520 - Fax www.lachoppers.com [email protected]