Kuryakyn 6745 User manual

PAGE 1
306745
DPF-MRK-003 REV A 8/7/18
ZOMBIE LEVERS FOR SOFTAIL, GLOSS BLACK 6745
866 277 9598 | [e-mail]
454 COUNTY ROAD VV SOMERSET, WI 54025
KURYAKYN.COM
INSTALLATION INSTRUCTIONS
THANK YOU FOR CHOOSING KURYAKYN!
Protect yourself and others from possible injury and property damage or loss. Pay close attention to all instructions, warnings, cautions, and notices regarding the installation, use, and care of this product.
THIS INDICATION ALERTS YOU TO THE FACT THAT IGNORING THE CONTENTS DESCRIBED HEREIN CAN RESULT IN POTENTIAL DEATH OR SERIOUS INJURY.
THIS INDICATION ALERTS YOU TO THE FACT THAT IGNORING THE CONTENTS DESCRIBED HEREIN CAN RESULT IN MINOR OR MODERATE POTENTIAL INJURY.
THIS INDICATION ALERTS YOU TO THE FACT THAT IGNORING THE CONTENTS DESCRIBED HEREIN MAY NEGATIVELY AFFECT PRODUCT PERFORMANCE AND FUNCTIONALITY OR
DAMAGE THE PRODUCT ITSELF OR THE PRODUCT TO WHICH IT IS BEING ATTACHED.
ENSURE THAT THE FOLLOWING PARTS HAVE BEEN INCLUDED IN THE KIT:
1Zombie Brake Lever 2Zombie Emblems
1Zombie Clutch Lever 2Grooved Emblems
1Alcohol Pad
YOU WILL ALSO NEED:
Snap-ring pliers, needle-nose pliers, grease, torx driver set, hex wrench set
THESE INSTALLATION INSTRUCTIONS CONTAIN IMPORTANT INFORMATION. ENSURE THE END USER RECEIVES THIS COPY AND IS AWARE
OF ITS IMPORTANCE FOR FUTURE USE.
STEP 1 Read and understand all steps in the instructions before starting the
installation. Park the motorcycle on a hard, level surface and turn off
the ignition. Let motorcycle cool. Remove main fuse.
A FACTORY SERVICE MANUAL WILL BE HELPFUL IN PERFORMING THIS
INSTALLATION. DO NOT ATTEMPT TO PERFORM THIS INSTALLATION
IF YOU ARE NOT CONFIDENT IN YOUR ABILITY TO COMPLETE ALL OF
THE STEPS IN THE PROCEDURE; CONSULT A TRAINED TECHNICIAN.
IMPROPER INSTALLATION COULD RESULT IN SERIOUS INJURY OR
DEATH.
ACCIDENTAL VEHICLE START-UP COULD CAUSE DEATH OR SERIOUS
INJURY, REMOVE THE MAIN FUSE BEFORE PROCEEDING.
AVOID DAMAGE TO THE MOTORCYCLE. PROTECT PAINTED SURFACES
WITH A SOFT CLOTH OR BLANKET.
CLUTCH SIDE
STEP 2 Refer to PIC 3. Loosen the clutch cable adjuster so the maximum
amount of slack is attained.
Note: Refer to motorcycle’s service manual for additional assistance in
loosening the clutch cable adjuster.
STEP 3 Remove snap ring and pivot pin from clutch lever perch. Set them
aside, they will be reused.
PIC 3
ZOMBIE
EMBLEM
CLUTCH (LEFT-SIDE)
LEVER
CLUTCH (LEFT-SIDE)
LEVER
BOTTOM VIEW OF LEVERS
TOP VIEW OF LEVERS
BRAKE (RIGHT-SIDE)
LEVER
BRAKE (RIGHT-SIDE)
LEVER
GROOVED
EMBLEM
PIC 1
PIC 2
PICTURES SHOWN ARE OF THE CHROME PARTS. INSTALLATION OF THE BLACK PARTS WILL BE THE SAME.

PAGE 2
306745
DPF-MRK-003 REV A 8/7/18
ZOMBIE LEVERS FOR SOFTAIL, GLOSS BLACK 6745
866 277 9598 | [e-mail]
454 COUNTY ROAD VV SOMERSET, WI 54025
KURYAKYN.COM
INSTALLATION INSTRUCTIONS
-CONTINUED-
STEP 4 Refer to PIC 4. Pull the cable housing as far out of the clutch perch as
possible and rotate the cable and housing away from the handlebar.
The lever may now be pulled free of the perch.
STEP 5 Refer to PIC 5. Align and place the clutch cable ferrule into the new
lever. Secure it in place with the OEM ferrule retaining clip.
STEP 6 Align and place the new lever into the clutch lever assembly. Be sure
that the plastic ferrule retaining clip stays flush during installation, and
that the clutch plunger is pressed in and does not bind.
STEP 7 Refer to PIC 6. Locate snap ring and pivot pin that was removed in Step
3. Reinstall the pivot pin and secure with the snap ring.
STEP 8 Readjust the clutch cable adjuster and replace the rubber boot or cover
over it. Compress the lever a few times to ensure that it is working
properly BEFORE starting the motorcycle.
BRAKE SIDE
STEP 9 Loosen the screws securing the brake (right) side handlebar master
cylinder assembly.
STEP 10 Remove snap ring and pivot pin from brake lever perch. Set them aside,
they will be reused.
STEP 11 Refer to PIC 7. Carefully remove the existing brake lever.
STEP 12 Align and place the new Brake Lever into the brake lever perch.
STEP 13 Refer to PIC 8. Locate snap ring and pivot pin that was removed in Step
10. Reinstall the pivot pin and secure with the snap ring.
STEP 14 Realign and fasten the master cyclinder assembly to the handlebar.
Fully tighten hardware.
STEP 15 Reinstall the main fuse. Compress the Brake Lever a few times to
ensure that the brakes and brake lights work properly BEFORE starting
the motorcycle.
STEP 16 Refer to PIC 9. Clean the flat spot on the levers with the included
alcohol pad and allow the area to dry.
PIC 4
PIC 5
PIC 6
PIC 7
PIC 8
FERRULE
RETAINING
CLIP
FERRULE

PAGE 3
306745
DPF-MRK-003 REV A 8/7/18
ZOMBIE LEVERS FOR SOFTAIL, GLOSS BLACK 6745
866 277 9598 | [e-mail]
454 COUNTY ROAD VV SOMERSET, WI 54025
KURYAKYN.COM
INSTALLATION INSTRUCTIONS
-CONTINUED-
ENSURE PROPER ADHESION OF THIS PRODUCT. REMOVE ALL GREASE,
OIL, BUGS, DIRT, AND OTHER DEBRIS (INCLUDING WAX AND POLISH)
FROM THE INSTALLATION AREA. KURYAKYN WILL NOT PROVIDE
WARRANTY COVERAGE ON PRODUCTS OR COMPONENTS LOST OR
DAMAGED DUE TO IMPROPER INSTALLATION.
DO NOT ATTEMPT THIS INSTALLATION IN TEMPERATURES BELOW 50°F
(10°C).
STEP 17 Choose which emblem you wish to install (Zombie or Grooved). Using
the back of your fingernail, rub the backing of the adhesive pad to
activate the catalyst.
STEP 18 Refer to PIC 9 and 10. Remove the adhesive backing and install the
emblem, ensuring that the aligning pin on the lever will be placed in
the hole in the emblem. Press and hold the emblem in place for one
minute, full bonding strength will occur in 24 hours.
Note: If the motorcycle is to be operated before the 24 hour cure time
has expired, use a good quality masking or painter’s tape over the
Emblem to assist in holding the Emblem in place until the cure time is
over.
IT IS THE INSTALLER’S RESPONSIBILITY TO ENSURE THAT ALL OF THE
FASTENERS (INCLUDING PRE-ASSEMBLED) ARE TIGHTENED BEFORE
OPERATION OF THE MOTORCYCLE. KURYAKYN WILL NOT PROVIDE
WARRANTY COVERAGE ON PRODUCTS OR COMPONENTS LOST DUE
TO IMPROPER INSTALLATION OR LACK OF MAINTENANCE. PERIODIC
INSPECTION AND MAINTENANCE ARE REQUIRED ON ALL FASTENERS.
LIMITED WARRANTY
Kuryakyn warrants that any Kuryakyn products sold hereunder, shall be free of defects in materials & workmanship for a period of one (1) year from the date of
purchase by the consumer excepting the following provisions:
1. Kuryakyn shall have no obligation in the event the customer is unable to provide a receipt showing the date the customer purchased the product(s).
2. The product must be properly installed, maintained & operated under normal conditions.
3. Kuryakyn shall not be liable for any consequential & incidental damages, including labor & paint, resulting from failure of a Kuryakyn product, failure to deliver, delay
in delivery, delivery in nonconforming condition, or for any breach of contract or duty between Kuryakyn & a customer.
4. Kuryakyn products are often intended for use in specific applications. Kuryakyn makes no warranty if a Kuryakyn product is used in applications other than intended.
5. Kuryakyn electrical products are warranted for one (1) year from the date of purchase by the consumer. L.E.D.’s contained in components of Kuryakyn products will
be warranted for defects in materials & workmanship for 3 years from the date of purchase whereas all other components shall be warranted for one (1) year.
6. All warranty claims must be directed to the place of purchase. Merchandise sold through internet auction sites or any other unauthorized reseller shall not carry a
Kuryakyn warranty. If unsure, please contact the place of purchase to verify they are an authorized Kuryakyn reseller.
RETURN POLICY
Merchandise determined to be defective may be returned up to one year from the date of purchase. Returns must be processed through original seller. Returned
merchandise for any other reason other than warranty claims must be in like new condition & subject to a 20% restocking fee. All returns are subject to inspection
for determination of full or partial credit. Any returned part that shows evidence of being used or installed contrary to manufacturer’s instructions, &/or subjected to
improper handling, packaging or return shipping by the customer, will not be eligible for exchange, refund or warranty consideration. All returned electrical items will be
inspected & tested. If electrical item is deemed functional, no credit will be issued & item will be returned. All sales are final on discontinued or closeout merchandise.
©2015 KURYAKYN HOLDINGS, LLC ALL RIGHTS RESERVED
KURYAKYN, KURYAKYN K logo and the marks appearing on this instruction sheet are registered and common law trademarks of Kuryakyn Holdings except noted third-party trademarks. A full listing of trademarks and trademark
registrations owned by Kuryakyn Holdings can be found at www.kuryakyn.com/legal-notice.
Emissions Notice: The California Air Resources Board (CARB) does not permit the use of aftermarket emission-related parts(s) that alter the performance of OEM emission-related devices unless CARB has issued an Executive
Order, other than on racing vehicles on closed courses. Check your local laws and manufacturer’s information.
Listed Manufacturers and product model names are for reference only. All product and company names are trademarks or registered trademarks of their respective holders. Use of them does not imply any affiliation with or
endorsement by them. All specifications are subject to change without notice.
For additional information on third-party product and company names, please consult our Web page at www.kuryakyn.com/legal-notice
PIC 9
PIC 10
MAKE SURE
PIN LINES UP
WITH HOLE
CLEAN
THIS
AREA