P4105 Installation Instructions
Contents
1. INSTALLATION AND OWNER S MANUAL ma national cycle P4105 Highway Bar for Kawasaki VN2000 Please read these instructions carefully and thoroughly before beginning work Before installing accessory carefully consider whether one possesses the necessary technical skills and workshop tools to complete the installation properly Otherwise any Motorcycle Retailer will be glad to install this accessory Dealers if installing the Highway Bar for a customer please supply them this manual It contains the instructional and reference material needed to properly maintain and use this product At time of purchase report any missing parts directly to National Cycle Inc The following information is necessary BAG NUMBER on outside of plastic fastener bag and DATE STAMP located on the end panel of the outer box Thank you The following symbols are used in these instructions Special notes and cautionary measures IE Tips for facilitation of operation control and adjustment as well as maintenance work 4mm Allan Wrench E gt 8mm Hex y Ratchet 10mm Socket 14mm Socket 1 2 Socket Torque Wrench Motorcycle Service Manual for Torque Specifications PARTS LIST Index Part No Description 1 90 970205 000 Highway Bar Left 90 970206 000 Highway Bar Right 51 513052 000 U Bolt 42 431010 000 Whizlock Nut Chrome 51 515965 000 CS M10 1 25 x 65 51 515951 000 CS M10 1 25 x 50 49 495531 000 Spacer Bag 795 Replacement Parts Item2. 4 Place U Bolt between the radiator and the down tube at the location shown in Figure 5 Threaded ends of U will face outward Install Whizlock Nuts 1 2 Socket Do not fully tighten Figure 5 Page 2 of 4 Figure 4 Place ae to inside of Highway Bar 10 114858 000 09 06 LEFT SIDE INSTALLATION IEJ To expose the engine mount bolts you need to loosen the wire connector cover See step 6 1 Remove the two bolts holding the wire connector cover Bolts will be reused 10mm Socket Figue 6 2 Remove the lower engine mount bolt 14mm Socket Figure 7 3 Install Highway Bar at lower engine mount point using the supplied 65mm bolt and one spacer Place spacer to the inside of Highway Bar Do not fully tighten 8mm Hex Figure 8 and 9 4 Use remaining 65mm bolt and spacer to install Engine Guard to upper mount point Spacer is located to the inside of Highway Bar Do not fuly tighten 14mm Socket and 8mm Hex Figure 6 On the Left Side due to tight clearances between the radiator and the down tube you must locate the point where the radiator is notched out slightly Figure 10 5 Repeat Step 3 to install U Clamp Do not fully tighten 1 2 Socket Figure 10 Figure 7 Figure 10 Page 3 of 4 10 114858 000 09 06 CHECK CLEARANCE AND TIGHTEN ALL FASTENERS Check clearance and operation of foot brake and shift lever Check clearance of Highway Bar at a full fork
3. ge 4 of 4 10 114858 000 09 06
4. lock left and right Adjust as necessary 12 Tighten all Screws left and right side at the lower mount points to the specified torque in your service manual Tighten the 4 Whizlock Nuts firmly 8mm Hex and 1 2 Socket Figure 11 13 Reinstall the Wire Connector Cover Hex Key Figure 12 Check hardware for tightness after you ride the motor cycle Re tighten fasteners if necessary MAINTENANCE CAUTION The high quality chrome finish of your National Cycle Highway Bar can be maintained with any quality chrome cleaner or polish applied with a soft cloth Check hardware for tightness regularly Never ride with loose mounting hardware Check to be sure your Highway Bar does not contact Figure 11 any part of the motorcycle at a full turn left and right Correct any problem before using the motorcycle If the additional of an accessory ies adversely affects your motorcycle s stability immediately remove the accessory ies Do Not ride a motorcycle that exhibits unsafe handling traits Have experienced service personnel correct any problem before riding with the accessory ies installed For further questions concern ing handling problems associated with an accessory ies contact your dealer motorcycle manu facturer or accessory manufacturer Figure 12 2005 National Cycle Inc PO Box 158 Maywood IL 60153 0158 USA 708 343 0400 Fax 708 343 0625 www nationalcycle com e mail info nationalcycle com Pa
5. s 3 7 NOoR WD O ANNAN IE Right and Left side of Motorcycle is determined while sitting on the bike PREPARATION 1 Insure that the motorcycle is on flat level ground 2 It is recommended that the motorcycle sit for at least one hour prior to installation to allow the engine to cool 3 To facilitate installing the U clamps to the down tube loosen the radiator frame cover 4mm Allan Wrench Figure 1 in During installation tighten all fasteners to hold Wait until you check all clearances and operation of the brake and shift lever to firmly tighten and torque all fasteners Figure 1 Page of 2 10 114858 000 09 06 INSTALLATION Right Side Highway Bar 1 Remove the bottom engine mount bolt Store bolts they will not be re used 14mm Socket Figure 2 2 Select the right side Highway Bar Using one supplied spacer and one 50mm bolt loosely install the Highway Bar at the lower mount point 8mm Hex Figure 3 3 Repeat procedure at upper engine mount bolt using the supplied 50mm bolt and one spacer Do not fully tighten bolts 14mm Socket 8mm Hex Figure 4 Install Upper U Bolt While installing the Whizlock Nuts step 4 below tighten the nuts evenly alternating left and right as you tighten When complete you want the same amount of threads exposed on the ends of the U to insure the bolt does not rotate Do not fully tighten at this time
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