ABM Superbike Original instructions

• www.ab-m.de ••• info@ab-m.de •
Superbike Kit
Installation and safety information
for
Kawasaki ZX-10 R
from model year 2016

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 2 of 19
Caution
Important safety advice:
Work undertaken on the steering and the brake system poses a safety risk. This work may only
be carried out by appropriately qualified personnel. Faulty work can have serious consequences
and may pose a threat to life and health. Only undertake this installation if you are sufficiently
qualified and have an official workshop manual as well as all relevant service notifications
available. Otherwise, we strongly recommend that the installation is carried out or at least
checked in a specialist workshop.
Brake fluid is toxic and may damage the surfaces of the fairing and other components. Use
suitable means to protect all parts against damage. Please observe the safety information of the
brake fluid manufacturer.
Use only fresh brake fluid taken from a sealed container. Always use new sealing rings which
comply with the specifications of the cable manufacturer. Never combine copper sealing rings
with aluminium connections.
ABS brake systems should be vented solely in a garage authorised by the vehicle manufacturer.
Any work in relation to the installation, removal and tightening torque of original parts should
always be carried out in compliance with the workshop manual.
To ensure safe function, it is essential that all contact areas of clamp connections are clean, dry
and damage free during installation. Important: Make sure that nothing gets onto these contact
surfaces which decreases friction
(e.g. oil, silicone, care products, etc.).
It is essential that all clamp screws are tightened with torque. The torque specifications refer to
dry screws and threads. The tight fit of all screw connections must also be checked at every
inspection.
It is your responsibility to check the product regularly and to determine if a service or
replacement is required.
Please remember that the top yoke is a safety-relevant part of your vehicle. Check the handlebar
as well as the rise and top yoke after a fall or collision and replace them completely at the
slightest indication of damage.
Never tie the vehicle at the handlebar.
The Superbike Kit requires registration.
This product has been designed for a standard vehicle. ABM® Fahrzeugtechnik GmbH makes no
warranty or guarantee of any kind for any damages whatsoever arising out of the combination
with other component parts not tested by ABM, as a consequence of improper installation or
inadequate maintenance.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 3 of 19
1
Preparation
Please read the entire safety information and installation manual carefully.
A motorcycle not securely positioned can fall over during the following work. Therefore, make sure
that the motorbike is positioned on solid, flat ground and is secured against falling over and rolling
away.
Keep children and pets away from the work area.
Protect removed parts from damage.
Never remove the upper triple clamp without first removing load from the front wheel as this could
damage the lower triple clamp.
Please note when disassembling individual parts which screws are used to fasten them. Keep these
parts and screws and unless specified otherwise, reuse when assembling.
2
Content and recommended accessories:
Special tool:
Torque wrench
Shorten fairing:
yes
Accelerator cables:
original
Steering stop
yes
Clutch cable / line:
new, enclosed
Shortening of
windshield:
no
Brake line:
new, enclosed
Riser/handlebar
BK3/0439
Choke cable:
not available
Handlebar extension
yes
Fairing pad
yes

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 4 of 19
3
Installation
Remove steering damper.
Remove both handlebar ends and the left-
hand rubber grip from the handlebar.
Remove the nut and washer and loosen the
clamp screws of the top yoke.
Unscrew the brake fluid reservoir holder.
Remove the safety screws of the
handlebars beneath the top yoke.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 5 of 19
Tip: Remove load from the front wheel and
cover the fairing.
Unclip the clutch cable at the lever.
Pull off the top yoke and place it onto the
side fairing on the left.
Drain the brake fluid of the brake unit
according to the manufacturer's
specifications.
Disconnect the brake line from the brake
pump.
Remove the switch units, armatures and the
brake pump on both sides.
Remove both original handlebars.
Tip:
Release the reservoir bracket, open the
hollow screw and let the fluid drip out of
the brake pump and brake line up to the
manifold at the radiator.
Close the fittings and the hand pump with
paper towels (see image).
Loosen the brake line and manifold above the
radiator and remove the complete line.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 6 of 19
Mount the provided brake line to the
manifold, align as per the original and
fasten.
Put some grease onto the sealing, insert it into
the manifold and install the original steel
cable.
Tightening torque 18 Nm
Attach the manifold to the bracket with the
screw and nut provided.
For this, slightly bend the holder.
Tip: For this release the holder.
Caution: To ensure a tension-free installation,
the brake line fittings can be aligned once at
the crimping.
Release the bracket and remove the screw.
Attach the steering stop and the bracket to the
frame using the screw, safety washers
provided.
Use thread-locking fluid (medium strength).
In doing so, push the steering stop completely
forwards in the direction of travel.
Tightening torque 6 Nm

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 7 of 19
Loosen the screws of the ignition lock using a
special tool or drill out.
Tip: Centre-punch and pre-drill using a drill
(3mm). Then drill out the screw head (8mm).
All the original parts for attaching the ignition
lock are no longer needed.
Attach the clamps with screws (M10) and
safety washers onto the top yoke.
Use thread-locking fluid (medium strength).
Tightening torque 28 Nm
Caution: The wide side of the clamps must
face forward.
Caution: The screws must not protrude into
the clamp area of the handlebar.
For attaching the ignition lock drill out both
holes to Ø 11 mm.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 8 of 19
Attach the ignition lock to the top yoke using
the spacer bushings, screws and washers
provided.
Tightening torque 18-21 Nm.
Align all parts before attaching.
Slightly drill out the screw heads (hexagon
socket) for theft protection.
Mount the two clamp screws to the top yoke.
Caution:
The lines of the armatures, switches and
operating elements must be routed
between the tank and fork.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 9 of 19
The clutch cable, the accelerator cables
and the brake line must be routed
between the fairing and fork.
Slide on the top yoke and attach using the
original nut and washer and the two clamp
screws (M8x20) (torque according to
manufacturer's specifications).
Tightening torque 18Nm
Slide the throttle grip onto the handlebar.
Insert the handlebar into the clamps, align and
attach lightly.
Slide the handlebar extensions with the
handlebar ends into the handlebar. Align
the writing and then fasten it.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 10 of 19
Slide all operating elements and armatures
onto the handlebar…
… and provisionally pre-assemble.
Remove the front tank fairing.
Attach the steering damper at the tank using the
provided shorter spacer bushing and screw.
When doing this, the original sleeve and plastic
washer are also screwed in again.
Tightening torque 18 Nm

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 11 of 19
Attach the steering damper onto the top yoke
using the provided longer spacer bushing and
screw.
Caution: With the electric steering damper
(model 2016 and later), the sleeve
provided (5mm) must also be used
between spacer bushing and screw.
Tightening torque 18 Nm
Lay the cable under the tank fairing so that
it can be attached with the bracket to the
damper as per original.
Screw in the tank fairing.
Attach the original brake fluid reservoir on the
brake pump using the provided holder (see
image).
After the final installation of the hand pump,
slightly bend the reservoir holder in such a way
that the reservoir is straight and cannot touch
the fairing.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 12 of 19
Remove the left and right plastic covering
according to the workshop manual.
Unscrew the black Phillips screws on both sides
completely.
Disconnect the plug connectors of the
indicators.
Remove the two mirrors.
Slightly lift the fairing and ...
... insert and align the fairing pads between
holder and fairing.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 13 of 19
Reattach the mirror using the longer screws
provided.
Tightening torque 6 Nm
Reconnect the plugs of the indicators and check
their functionality.
Insert the black Philips screws on both sides.
Install the left and right plastic covering
according to the workshop manual.
Cut out the template (page size in DIN A4).
To mark the cutting line remove the upper
screws of the windshield...

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 14 of 19
... place the template on the fairing and align it
with the screw.
Mark the cutting line.
Remove template and reinsert the screw of the
windshield.
Cover vehicle.
Shorten the fairing on the right and left side
along the marked line.
Tip: Use a jigsaw or a grinder.
Deburr the edges using a file or sandpaper.
If required, paint the edges.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 15 of 19
Before bleeding the brake, check that the brake
lever can be pulled up to the handle and under
no circumstances touches other parts.
After mounting the brake line and the hand
pump, the complete brake system must be bled
according to the installation instructions of the
manufacturer.
Install the provided clutch cable.
TIP: Unclip the cable, unscrew the holder from
the engine and...
... remove it from the original cable.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 16 of 19
Connect the new to the old clutch cable
with a cable tie.
Pull the old cable through the fairing, thus
pulling in the new cable at the same time.
Clip in the clutch cable again. Attach and
adjust it with the holder.
The final assembly of the operating
elements requires the drilling of holes for
the centring pins. To do this, align the
operating elements and mark the positions
for the centring pins (push onto the pins
using grease). Now, centre-punch the
marked position and drill a hole (diameter
and depth are based on the centring pin).
Before the final fixing of the handlebar and
the armatures, make sure that the
handlebar does not come into contact with
any other parts (e.g. fairing or tank), even
in maximum steering angle. Clip the clutch
cable into the armature.
Then tighten the screws of the clamps.
Tightening torque 24 NM
Assemble the cover caps.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 17 of 19
Make sure that all operating elements present on the handlebar are adequately
positioned, even in maximum steering angle. The hand brake cylinder and the
storage tank must be located in an adequate operating position.
Pay attention to the freedom of movement of the handlebar, its mounted parts
and adequate steering angle to each side. The handlebar must be able to be
moved easily from left to right. Check the free play of the accelerator cables: In
maximum steering angle to both sides and with the engine running, the motor
speed must not change.
After completing the work, the firm fit, function and tightness of all components
and screws must be checked. Make sure that there is sufficient brake fluid in the
reservoir. Also check the front wheel's freewheel and the functionality of the
brake system. Further, the function of the clutch, the throttle grip, the electric
system and the anti-theft devices must be checked.
Afterwards, a test drive must be done! After completion of the test drive, all
screw connections must be re-checked for firm fit, tightness and all movable
parts for adequate freedom of movement. Re-test the front wheel's freewheel
and check the brake system for overheating. Check the brake fluid level in the
reservoir for significant changes.
After ca. 100km, the firm fit of all screw connections of the handlebar must be
re-checked against the specified tension values.

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 18 of 19

Installation manual Superbike™for Kawasaki ZX-10 R model 2016-
• Revision: 00 • 30/01/2020 • © ABM Fahrzeugtechnik GmbH Page 19 of 19
Table of contents
Other ABM Motorcycle Accessories manuals