Kleinn Air Horns CANX3-KIT User manual
CANX3-KIT
Installation and Operation Manual
Go to Table of Contents PG 3/44 REV: A (9/4/2020)
Table of Contents
1. LIST OF FIGURES .................................................................................................................................................5
2. How to Use this Manual .....................................................................................................................................6
2.1. Interactive Manual using Adobe Reader....................................................................................................6
2.2. Your Kit SKU Number and this Manual.......................................................................................................6
2.3. Illustration/Photo Details and Orientation.................................................................................................6
3. Safety First..........................................................................................................................................................7
4. Application Chart................................................................................................................................................8
4.1. 100% Direct Bolt-On Vehicle List................................................................................................................8
4.2. **Excluded Vehicles ...................................................................................................................................8
4.3. Aftermarket Product Compatibility............................................................................................................8
5. Installation Overview..........................................................................................................................................9
5.1. QUICK INSTALL OUTLINE.............................................................................................................................9
5.2. Kit Layout and Locations.......................................................................................................................... 10
5.3. Approximate Installation Time................................................................................................................ 10
6. List of Tools and Supplies ................................................................................................................................ 11
6.1. Standard Tool List (Required).................................................................................................................. 11
6.2. Special Tool List (Recommended) ........................................................................................................... 11
6.3. Shop Consumables List (Recommended)................................................................................................ 11
7. Parts List .......................................................................................................................................................... 12
7.1. Before Starting, Review Parts List ........................................................................................................... 12
7.2. Pre-Packaged Electro-Mechanical Kit Items............................................................................................ 12
7.3. Air Fittings and Related Items ................................................................................................................. 13
7.4. Electrical Small Components and Related Items..................................................................................... 14
7.5. Bolt-On Mounting Brackets & Special Hardware .................................................................................... 15
7.6. Hardware, Fasteners and Soft Parts........................................................................................................ 16
8. On-Vehicle Mechanical Assembly Steps.......................................................................................................... 19
8.1. Plan Location of Quick Connect Air Coupler............................................................................................ 19
8.2. Remove Passenger side Rear Fender ...................................................................................................... 19
8.3. Remove Driver side Rear Fender............................................................................................................. 21
8.4. Air Tank Brackets - Installation................................................................................................................ 21
8.5. Air Tank Fittings - Bench Assembly.......................................................................................................... 24
8.6. Air Tank - Installation............................................................................................................................... 25
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Installation and Operation Manual
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8.7. Bench Assemble Compressor with Bolts and X3-102.............................................................................. 26
8.8. Bench Assemble Compressor Bracket and Rubber Bushings.................................................................. 28
8.9. Air Compressor Bracket - Installation...................................................................................................... 29
8.10. Air Compressor - Installation................................................................................................................... 32
8.11. Air Horn - Installation .............................................................................................................................. 34
8.12. Connect Remote Quick Connect Kit to Vehicle ....................................................................................... 38
9. On-Vehicle Electrical Installation..................................................................................................................... 39
9.1. Relay and Fuse Diagram for Air Horn System.......................................................................................... 39
9.2. Review suggested Wire Routing for Air Horn System ............................................................................. 40
9.3. Disconnect Vehicle Battery(s).................................................................................................................. 40
9.4. Connect Wiring to Relay(s) and Fuse(s), then Attach to Vehicle............................................................. 40
9.5. Install Horn Button .................................................................................................................................. 41
9.6. Connect Air Horn Solenoid(s) .................................................................................................................. 41
9.7. Pressure Switch ....................................................................................................................................... 41
10. Initial Testing of Kit.......................................................................................................................................... 42
10.1. Reconnect Vehicle Battery(s) .................................................................................................................. 42
10.2. Test Air Compressor ................................................................................................................................ 42
10.3. Test Train Horns....................................................................................................................................... 42
10.4. Test Quick Connect Coupler .................................................................................................................... 42
10.5. Re-install Rear Fenders............................................................................................................................ 42
11. General Operation of Kit ................................................................................................................................. 43
11.1. Compressor Operation ............................................................................................................................ 43
11.2. Horn Operation........................................................................................................................................ 43
12. Routine Maintenance...................................................................................................................................... 43
13. Warranty Information ..................................................................................................................................... 44
CANX3-KIT
Installation and Operation Manual
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1. LIST OF FIGURES
Figure 1 –Top View Showing Kit Layout (2018 X3 2 Door Shown) ......................................................................... 10
Figure 2 –Passenger Rear Fender Removal (fasteners on top of fender) .............................................................. 19
Figure 3 –Passenger Rear Fender Removal (fasteners behind door and fender) .................................................. 19
Figure 4 –Passenger Rear Fender Removal (below tail light)................................................................................. 20
Figure 5 –Passenger Rear Fender Removal (fender resting on tire); Air Tank shown installed............................. 20
Figure 6 –Air Tank Bracket Mounting Locations (side view) .................................................................................. 21
Figure 7 –Air Tank Bracket Mounting Locations (top view) ................................................................................... 21
Figure 8 –Front Air Tank Bracket stops at corner Gusset (Shown with Air Tank) .................................................. 22
Figure 9 –Installing Front Air Tank Brackets, Exploded View ................................................................................. 22
Figure 10 –Installing Rear Air Tank Bracket, Exploded View.................................................................................. 23
Figure 11 –Installing Rear Air Tank Bracket, Proper Bolt Orientation (partial bracket shown) ............................. 23
Figure 12 –Air Tank Fittings installed on Air Tank, Exploded View ........................................................................ 24
Figure 13 –Air Tank Fittings Orientation (from above vehicle) .............................................................................. 24
Figure 14 –Installing Air Tank onto Brackets, Exploded View ................................................................................ 25
Figure 15 –Air Compressor Leader Hose Support Bracket installed (example zip tie routing shown) .................. 26
Figure 16 - Air Compressor with Bolts and X3-102 (Shown with Air Filter and no Leader Hose) ........................... 27
Figure 17 - Air Compressor Bracket with Rubber Grommets Installed................................................................... 28
Figure 18 –Air Compressor Bracket Mounting Locations (side view w/o fender –CARB Version shown)............ 29
Figure 19 –Air Compressor Bracket Mounting Locations (top view)...................................................................... 29
Figure 20 –Installing Air Compressor Bracket, Exploded View............................................................................... 30
Figure 21 –Air Compressor positioned temporarily in place (Shown installed on CARB Vehicle) ......................... 30
Figure 22 –Air Compressor Clearance Adjustment (Shown installed on CARB Vehicle)........................................ 31
Figure 23 –Air Compressor Bracket final installed (Shown installed on CARB Vehicle)......................................... 31
Figure 24 –Air Tubing Route from Air Compressor to Air Tank.............................................................................. 32
Figure 25 –Installing Air Compressor onto Bracket; Exploded View (shown without Leader Hose) ..................... 33
Figure 26 –Air Compressor Filter Remote Tubing shown attached (example vehicle).......................................... 33
Figure 27 –Disassembly of Air Horn by Separating Trumpets................................................................................ 34
Figure 28 –Carriage Bolts temporarily taped in place on Horn Bracket................................................................. 34
Figure 29 –X3-302 with Rubber U-Trim installed, exploded view.......................................................................... 34
Figure 30 –Sway Bar Bolts to remove and Brake Line Bolt (looking from above).................................................. 35
Figure 31 –Air Horn Bracket Installed below Brake Lines....................................................................................... 35
Figure 32 –Installing Trumpet Support Clamp and Trumpets, Exploded View ...................................................... 36
Figure 33 –Installing Air Horn Driver with Tubing attached, Exploded View ......................................................... 37
Figure 34 –Final tightening of Air Horn Brackets and Air Horn .............................................................................. 37
Figure 35 –Final installation of 102 Air Horn (X3 Turbo R shown) ......................................................................... 38
Figure 36 –Example of Air Coupler Mounted to Bumper....................................................................................... 38
Figure 37 –Suggested Ignition Relay Diagram for Air Horn System ....................................................................... 39
Figure 38 –Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch ........................................... 40
Figure 39 –Relay and Fuse location example behind Passenger seat (2019 X3 Turbo RC Shown) ........................ 40
Figure 40 –Recommended install location for Air Horn Button............................................................................. 41
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Installation and Operation Manual
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2. How to Use this Manual
2.1. Interactive Manual using Adobe Reader
It is recommended to open this digital PDF using Adobe Reader ® to take advantage of following key features:
•Hyperlinks (blue underlined text) allow access to additional content via internet; click/tap to activate
oIncludes Installation Figures and “Figure xx”
•Table of Contents page allows easily navigating this manual; click/tap any section line to go to it
•Bookmarks allow quickly navigating to any section; click/tap
•Zoom IN on pictures by pressing “CTRL and +” at same time on PC, or pinch in on smart devices
•Zoom OUT on pictures by pressing “CTRL and -”at same time on PC, or pinch out on smart devices
To install Adobe Reader ®
On PC, or Mac
•visit https://get.adobe.com/reader/otherversions/
On Android, iPhone/iPad, and Windows devices,
•visit https://acrobat.adobe.com/us/en/acrobat/mobile-app.html
2.2. Your Kit SKU Number and this Manual
This manual covers installation, testing, and operation of following SKU part numbers
2.2.1. CANX3-KIT (i.e., 102b Train Horn with On-Board Air System)
2.2.2. CANX3-OBA (i.e., On-Board Air System)
NOTE: Illustrations and pictures contained herein may represent only one kit part number.Where
critical differences exist between kits (i.e., different parts, orientation, mounting points, etc.), additional
text, or necessary graphics are provided to minimize confusion.
Parts list explicitly state kit differences with (BOLD TEXT) inside parenthesis, shown below part number.
2.3. Illustration/Photo Details and Orientation
This manual may use digitally created illustrations, and/or actual photos of example vehicle. These graphics may
not include exact items found on your vehicle (i.e., electrical wiring, fuel lines, body panels, etc.). Illustrations
typically will be missing details and are for clarity to show critical mounting locations and orientation on vehicle.
Throughout manual yellow arrows with text reading “FRONT”, may be present over
illustrations and pictures. These arrows specify direction toward front of vehicle and
provide clarity to how illustration is viewed.
End of Section
FRONT
CANX3-KIT
Installation and Operation Manual
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3. Safety First
Read manual thoroughly before starting installation of this kit. Verify you have all parts listed and that you
clearly understand this installation procedure. Contact Kleinn technical support for any questions.
Installation of this kit requires moderate mechanical aptitude; seek professional help if you’re not competent
using hand tools in tight uncomfortable spaces, and around possibly rusted and sharp vehicle parts.
Before starting, obtain proper tools required to perform installation correctly, adequate lighting, eye protection,
hearing protection for operating train horns, and hand protection to guard against sharp edges and metal burrs,
which may be present on kit parts and vehicle parts.
Throughout this manual the following words may be used; be aware of their meaning and application.
CAUTION: means damage could occur to vehicle, or kit parts during, or after installation
WARNING: means injury could occur to you or others, including damage to vehicle, or kit parts
DANGER: means serious injury or death could occur to you or others during installation
End of Section
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Installation and Operation Manual
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4. Application Chart
4.1. 100% Direct Bolt-On Vehicle List
CANX3-KIT is a 100% direct bolt-on aftermarket product for Can-Am vehicles listed in below chart; every effort
has been made to verify correct fitment on these vehicles in their factory, non-modified conditions.
MODEL YR
MODEL
DRIVE
ENGINE
BODY
TRIM
2017-2020
MAVERICK X3
ALL
ALL
ALL
ALL**
NOTE: All vehicles listed may require drilling holes for ground wires and installing switches, based on
preference of installed switch locations and wire grounding points.
4.2. **Excluded Vehicles
4.2.1. N/A
4.3. Aftermarket Product Compatibility
4.3.1. This kit has been designed to be compatible with following products from leading manufacturers:
•Aftermarket cages that discard OE rearmost bolt-on chassis tubes (i.e., Rack down tubes)
•Aftermarket front shock tower braces and bulkheads (i.e., S3 PowerSports), which bolt ONLY in front of
shocks, or below frame (i.e., cannot attach above sway bar bolts)
4.3.2. This kit has NOT been designed to be compatible with any of the following products:
•Exhaust systems or high-performance intake systems, including super/turbo chargers
•Suspension systems (i.e., larger shocks/springs, control arms, sway bar upgrades, etc.)
•Winches
•Oversized tires
•Oversize rear fenders
•Many other systems/parts no listed
NOTE: Review this manual in full before unpacking items and verify correct space and mounting locations
exist with your aftermarket product(s). To install this kit alongside your other aftermarket product(s),
modification to included parts, your vehicle, or aftermarket product(s) may be required.
End of Section
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Installation and Operation Manual
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5. Installation Overview
5.1. QUICK INSTALL OUTLINE
For person(s) with experience installing Kleinn bolt-on kits, CANX3-KIT can be quickly installed following
below:
1. Layout and organize all parts on bench
2. Select location for Quick Connect Air Coupler
3. Remove Driver and Passenger Rear Fenders
4. Install Air Tank Brackets (X3-201, 202, 203, & 204)
5. Bench assemble Air Fittings and Air Tubing to Air Tank
6. Install Air Tank
7. Bench assemble Air Compressor Bracket (X3-101)
8. Bench assemble Air Compressor and Leader Hose Bracket (X3-102)
9. Install Air Compressor Bracket (X3-101)
10. Install Air Compressor
11. Prepare Front Sway Bar area for Air Horn
12. Install Air Horn Brackets (X3-301 & 302)
13. Install Air Horn
14. Connect air lines and wirings
15. Install Quick Connect Coupler and route Air Tubing
16. Route Wiring, install Relay, and install Horn Button
17. Test system and adjust, as needed
18. Re-install both rear fenders
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5.2. Kit Layout and Locations
CANX3-KIT consists of following sub-systems, located on vehicle, as follows:
ITEM
DESCRIPTION
MOUNTING LOCATION
APPROX.
INSTALL TIME
1
6350RC Air Compressor
Rear Frame, Driver Side
(behind fender and below Rack)
1-2 Hours
2
1 Gal. Air Tank
Rear Frame, Passenger Side
(behind fender and below Rack)
1-2 Hours
3
102 Series Dual Horn with Air Solenoid
Front Sway bar Mounts,
(directly behind front shocks)
2-4 Hours
Figure 1 –Top View Showing Kit Layout (2018 X3 2 Door Shown)
5.3. Approximate Installation Time
CANX3-KIT is a multi-faceted product consisting of multiple mechanical, electrical, and pneumatic
components.
For a typical home mechanic, auto enthusiast, or technician installing a Kleinn Bolt-On kit for first time, a
professional installation job with setup and testing of final product, is estimated to take:
•4-8 Hours
End of Section
1
3
FRONT
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6. List of Tools and Supplies
6.1. Standard Tool List (Required)
6.1.1. Basic mechanic’s 3/8” drive socket sets with extensions
•Inch Size Sockets (1/4” – 1” Hex)
•Metric Size Sockets (6mm –20mm Hex)
6.1.2. Basic mechanic’s combination wrenches (box/open-end)
•Inch Size Wrenches (1/4” – 1” Hex)
•Metric Size Wrenches (6mm –20mm Hex)
6.1.3. Basic mechanic’s screwdriver set (Philips, Flat Head)
6.1.4. Torx driver, or socket set (T15-T30)
6.1.5. Diagonal Cutter/Wire Cutter Pliers
6.1.6. Wire Strippers
6.1.7. Wire Terminal Crimpers
6.1.8. Slip-Joint Pliers
6.1.9. Utility Knife, or Utility Razor blade
6.1.10. Magnetic retrieval tool
6.2. Special Tool List (Recommended)
6.2.1. 10-100 ft.-lb. torque wrench
6.2.2. 20-150 in.-lb. torque wrench
6.2.3. Multi-Meter for 12V DC electrical systems, or equivalent
6.2.4. 12V DC Test Light, or equivalent
6.2.5. Trim Panel Tool, for removing wiring and body clips, when needed
6.3. Shop Consumables List (Recommended)
6.3.1. Quality Electrical tape
6.3.2. Di-electric grease for electrical connections
6.3.3. Heat Shrink tubing for electrical connections
6.3.4. Blue Loctite (i.e., Loctite PN 242), or equivalent
6.3.5. Sand Paper, or Wire Brushes for installing ground wires
6.3.6. Extra plastic zip ties > 6” long
6.3.7. Extra NPT sealant (i.e., Kleinn Air Horn Juice, Teflon tape, etc.)
6.3.8. Touch-up paint for frame/chassis
6.3.9. Typical cleanup supplies
End of Section
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7. Parts List
7.1. Before Starting, Review Parts List
Unpackage and organize Kit across a large work area and verify all parts are included, as listed below.
Contact Kleinn support if any questions arise.
7.1.1. Review pre-packaged Kit items (i.e., K1, K2, etc.)
7.1.2. Review Air Fittings and Tubing (i.e., F1, F2, etc.)
7.1.3. Review Wiring and Accessories (i.e., E1, E2, etc.)
7.1.4. Review Bolt-On Mounting Brackets (i.e., M1, M2, etc.)
7.1.5. Review Hardware/Fasteners (i.e., H1, H2, etc.)
7.1.6. Familiarize yourself with how parts assemble
7.2. Pre-Packaged Electro-Mechanical Kit Items
NOTE: Items in this section come in their own packages and may include additional items inside package
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
K1
1
6350RC
6350RC Air Compressor Kit, with
included hardware, and remote
air supply line
K2
1
6230RT
Air Tank, 4” OD, 1 Gal., 5-Port
K3
1
102-1
102 Series Air Horn Kit, with
included solenoid/valve
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7.3. Air Fittings and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
F1
1
2151
(view location on Air
Tank)
1/4" NPT PRESSURE SWITCH
F2
1
54440
(view location on Air
Tank)
1/4" NPT "T" MANIFOLD, FEMALE
F3
2
51414NPTL
(view location on Air
Tank)
1/4" NPT X 1/4" NPT FEMALE, 90
DEG. ELBOW
F4
1
52835
(view location on Air
Tank)
1/4" NPT DRAIN VALVE
F5
1
52175
(view location on Air
Tank)
1/4" NPT, 175 PSI SAFETY VALVE
F6
1
51414
(view location on Air
Tank)
1/4" NPT X 1/4" TUBE FITTING,
STRAIGHT
F7
2
51414L
(view location on Air
Tank)
1/4" NPT X 1/4" TUBE FITTING, 90
DEG. ELBOW
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F8
1
51414F
1/4" NPT X 1/4" TUBING FEMALE,
STRAIGHT
(USED ON COMPRESSOR LEADER
HOSE END)
F9
1
25014
1/4" AIR TUBING, 20 FT. LONG
(USE 6 FT. FOR COMPRESSOR, 14
FT. FOR AIR HORN)
F10
1
KLEINN AIR HORN
JUICE
THREAD SEALENT FOR NPT
FITTINGS
F11
1
INF-1
INFLATOR KIT, WITH AIR HOSE AND
BAG
7.4. Electrical Small Components and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
E1
1
WIRE KIT
FULL WIRE KIT, WITH ELECTRICAL
CONNECTORS AND ZIPTIES
E2
1
1/8" OD X 15FT.
LONG
1/8" WIRE LOOM, CORRUGATED
AND SPLIT
E3
1
1/4" OD X 15FT.
LONG
1/4" WIRE LOOM, CORRUGATED
AND SPLIT
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E4
1
1" OD X 1FT. LONG
1” WIRE LOOM CORRUGATED
AND SPLIT
E5
1
321-W
HORN ROCKER SWITCH, WITH
BACKLIT HORN LOGO
7.5. Bolt-On Mounting Brackets & Special Hardware
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
M1
1
X3-101
COMPRESSOR BRACKET,
WELDMENT
M2
1
X3-102
LEADER HOSE SUPPORT
BRACKET, CUT
M3
1
X3-201
TANK BRACKET, REAR MOUNT,
CUT AND FORMED
M4
1
X3-202
TANK BRACKET, FRONT-INNER
HALF, CUT AND FORMED
M5
1
X3-203
TANK BRACKET, FRONT-OUTER
HALF, WELDMENT
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M6
2
X3-204
SPACER, BRACKET HALF,
MACHINED
M7
1
X3-301
HORN BRACKET, CUT AND
FORMED
M8
1
X3-302
HORN STABILIZER BRACKET, CUT
AND FORMED
7.6. Hardware, Fasteners and Soft Parts
NOTE: Pictures only indicative, not to scale and may not represent exact item
ITEM
QTY.
PART
NUMBER/SIZE
DESCRIPTION
PICTURE
H1
2
1/4"-20 X 1"
SQUARE NECK BOLT, GRADE 2,
ZINC-PLATED
H2
2
1/4" ID X 0.63" OD
FLAT WASHER, SAE, ZINC-
PLATED
H3
2
1/4"
LOCK WASHER, SPLIT, ZINC-
PLATED
H4
2
1/4"-20
HEX NUT, GRADE 2, ZINC-
PLATED
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H5
9
5/16"-18 X 1.00"
LONG
SQUARE NECK BOLT, GRADE 2,
ZINC-PLATED
H6
2
5/16"-18 X 2.50"
LONG
SQUARE NECK BOLT, GRADE 2,
ZINC-PLATED
H7
4
5/16" ID X 0.88" OD
FLAT WASHER, USS, ZINC-
PLATED
H8
7
5/16" ID X 0.69" OD
FLAT WASHER, SAE, ZINC-
PLATED
H9
11
5/16"
LOCK WASHER, SPLIT, ZINC-
PLATED
H10
11
5/16"-18
HEX NUT, GRADE 2, ZINC-
PLATED
H11
6
M6 X 1 X 20MM
LONG
BUTTON HEAD TORX SCREW,
BLACK-OXIDE
H12
2
M6 X 1 X 18MM
LONG
COUPLING NUT, CLASS 8, ZINC-
PLATED
H13
2
M6 X 1MM
NO-SLIP, CLIP-ON BARREL NUT
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H14
2
M5 X 0.8 X 10MM
LONG
BUTTON HEAD CAP SCREW,
BLACK-OXIDE
H15
8
1/4" ID X 0.63" OD
FLAT WASHER, SAE, BLACK-
OXIDE
H16
2
M6
LOCK WASHER, SPLIT, BLACK-
OXIDE
H17
2
1 1/16" OD X 1/2" ID
X 3/8" WIDTH
PRESS-IN RUBBER GROMMET
H18
1
1 FT. LONG
RUBBER TRIM (NARROW "U")
H19
8
#10 ID X .69" OD
FLAT WASHER, FENDER, ZINC-
PLATED
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8. On-Vehicle Mechanical Assembly Steps
8.1. Plan Location of Quick Connect Air Coupler
8.1.1. Before installing Brackets, review how kit installs and decide whether to install coupler to vehicle body,
frame, or onto supplied brackets; this facilitates later routing Air Tubing and attaching Coupler.
NOTE: Some installers may choose to directly fasten Quick Connect Coupler to Air Compressor, Air Tank,
or Air Horn Brackets by using self-tapping screws or drilling a hole for Coupler itself. Although this is
common practice, modification of Brackets in any way voids their warranty.
8.2. Remove Passenger side Rear Fender
8.2.1. Remove seven (7) T30 screws from top of fender and corner trim, as shown circled in below figure.
8.2.2. After removing screws, remove five (5) accompanying body clips on top of rear fender and two (2) on
corner trim.
CAUTION: Use care removing body clips and corner trim; corner trim has a hidden clip on backside. All
items removed will be re-used later.
Figure 2 –Passenger Rear Fender Removal (fasteners on top of fender)
8.2.3. Remove three (3) additional T30 screws; two (2) located behind passenger door and one behind panel in
wheel-well area as shown below. Un-clip wire loom from body panel for ease of moving fender.
Figure 3 –Passenger Rear Fender Removal (fasteners behind door and fender)
2X Trim Screws
5X Fender Screws
Behind Door
Behind Fender
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8.2.4. Remove single T15 screw holding rear of fender near inside of brake light, as shown below.
Figure 4 –Passenger Rear Fender Removal (below tail light)
8.2.5. Pull fender outwards from body and rest on tire to reduce stress on Brake Light Wiring, as shown below.
Figure 5 –Passenger Rear Fender Removal (fender resting on tire); Air Tank shown installed
T15 Screw
FRONT
Brake Light
Wiring Still
Connected
Middle Slot
used later
Sec 10.5
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