Pro-Series Aluminum Water Box
Contents
1. SIR RACING PERFORMANCE PRODUCTS amp ACCESSORIES Pro Series Aluminum Water Box PART RK16091 1 We strongly recommend the use of a service manual to familiarize yourself with the various components and procedures involved with this installation Please note that some of the original clamps hoses and hardware removed in the disassembly process will be used in the installation process These instructions have been written in step by step format and refer to illustrations We suggest reading through the instructions entirely before performing installation Please follow these step by step instructions and illustrations carefully APPLICATION S Kawasaki Ultra 300 260 250 xxx ALLOW ENGINE TO COOL COMPLETELY BEFORE PERFORMING INSTALLATION xxx NOTE Installation of this kit in 2008 2010 models requires RIVA Free Flow Exhaust Kit part RK16090 08 as referenced in these instructions INSTALLATION INSTRUCTIONS Remove hoses 3 attached to catch can Remove bolts 2 securing oil catch can to intercooler Remove catch Remove seats Remove rear storage tray grab handle can from engine compartment Intercooler air inlet hose Cap nuts securing storage tray grab handle ae TULLE f m Oil catch A 2 7 a Il catch can 4 f 7 E 2008 2010 models only Disconnect cooling line TIP Replace cap nuts on studs for storage tray to secured to top of intercoole2. pipe from muffler and set aside 2008 2010 models only Disconnect cooling line Loosely install stock clamps over water box inlet and from fitting at front of stock water box two of the supplied clamps over water box outlet Thoroughly clean exhaust tail pipe with a non residual cleaner Insert exhaust tail pipe into water box coupler Align tail pipe with exhaust pipe and exhaust gasket s Secure with stock bolts NOTE Apply red Loctite to bolts Torque bolts to 33 ft lb 45 Nem Check alignment of water box at coupler between exhaust tail pipe and water box inlet Tighten clamps securing coupler NOTE Do not over tighten clamp 2008 2010 models only Refer to RIVA Free Flow Exhaust Kit installation instructions to complete installation 2007 amp 2011 models only Reconnect water box outlet hose NOTE Do not over tighten clamp Remove water box Retain silicone coupler Replace intercooler NOTE Make sure tab at lower rear of intercooler is under bracket Apply blue 2008 2010 models only Remove fitting from front of y 9 Loctite to bolts Torque bolts to 22 ft lb 30 Nem stock water box and install into supplied water box NOTE Apply pipe thread sealant to fitting threads i aie Reconnect intercooler cooling lines bypass hoses inlet Do not over tighten fitting amp outlet hoses and reconnect temperature sensor 2011 models only Install supplied block off fitting NOTE Do not over tighten clamps into
3. iability is expressly limited to the repair or replacement of the components contained within or associated with this kit RIVA Racing agrees to repair or at RIVA s option replace any defective unit without charge if product is returned to RIVA Racing freight prepaid within the warranty period Any equipment returned which in RIVA s opinion has been subjected to misuse abuse overheating or accident shall not be covered by this warranty RIVA Racing shall have no liability for special incidental or consequential damages or injury to persons or property from any cause arising from the sale installation or use of this product No other warranty express or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose applies Various states do not allow for the limitation of incidental or consequential damages and therefore the above exclusion or limitation may not apply to you Warranty does not include the expenses related to freight or transportation of parts or compensation for any inconvenience or loss of use while being repaired A copy of the original invoice and a Return Authorization Number RA must accompany all warranty claims Warranted replacement parts will be returned freight collect Word doc Part RK16091 1 H1 5 9 11 3
4. r prevent injury while performing work Disconnect intercooler air inlet hose left side of intercooler Word doc Part RK16091 1 H1 5 9 11 Disconnect primary bypass valve hose and over boost bypass valve hose from intercooler Disconnect intercooler inlet temperature electrical sensor Over boost bypass valve hose Primary bypass valve hose Intercooler air outlet hose Disconnect intercooler air outlet hose Disconnect cooling line secured to bottom center section of intercooler Remove bolts 2 securing intercooler to mounting bracket Bolts securing intercooler to hull Intercooler cooling line bottom center Word doc Part RK16091 1 H1 5 9 11 Carefully slide intercooler forward towards exhaust until tab at bottom on rear of intercooler clears securing bracket N i Tab securing intercooler to hull Intercooler cooling line under air outlet Remove second cooling line secured to bottom right side of intercooler under intercooler air outlet Remove intercooler by rotating air outlet side upward while lifting Remove exhaust hose between stock water box muffler and exhaust outlet tube Inside craft at engine remove the four M10 bolts securing exhaust tail pipe to exhaust pipe Exhaust Tail Pipe Bolts Exhaust Tail Pipe Loosen clamps securing coupler between exhaust tail pipe and water box Remove exhaust tail
5. supplied water box NOTE Apply pipe thread Replace oil catch can NOTE Apply blue Loctite to sealant to fitting threads Do not over tighten threads Torque bolts to 78 in lb 8 8 Nem fitting Reconnect catch can hoses 3 Install stock silicone coupler onto water box inlet Tip Apply glass cleaner to inside of coupler before installing Replace storage tray grab handle NOTE Apply blue Loctite to studs Do not over tighten nuts Install water box into hull and secure Check bilge for tools rags etc Run craft on a flush kit 2008 2010 models only Install and secure cooling to check for proper operation line to fitting at front of water box NOTE Do not over tighten clamp Remember the water belongs to everyone Please ride responsibly and respect the environment Technical Support For answers to questions regarding installation or trouble shooting RIVA Performance Products contact RIVA Technical Support directly at 954 247 0705 or by e mail at tech _support rivamotorsports com Limited Warranty RIVA Pro Series Aluminum Water Boxes carry a 1 year limited warranty to the original purchaser They are warranted to be free of defects in materials and workmanship under normal use and service Customer modified components will be void of warranty This warranty is limited to defects in the primary components only Finish and or wear marks in or on primary components are not covered under this warranty RIVA Racing s l
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