LSL ZGT40A Install guide

Fitting Instruction
Article-No. : 120K130
Product : Super Bike Conversion Kit
Model : Kawasaki GTR 1400 2008Æ
Type : ZGT40A
Important:
Read this instruction manual carefully and mind all warnings and tips. You should do this work
only if you‘re qualified; otherwise we recommend this mounting to be done by a professional
workshop. Improperly mounting of this kit can reduce the driveability of the motorcycle and may
be a risk to your health and life.
Special works are marked with the following signs. Please take special care on these works.
Warning! Important mounting instruction. It shows risks to your life and health.
LTips for mounting and maintenance or to avoid damage.
Fitting:
Mounted conversion kit
LThe battery ground should be disconnected before working on electric wiring and switches!
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Remove brake-hose(s). Caution: avoid brake fluid on painted surfaces! Any work on the
brake system or bleeding the system should be done by an authorized dealer or a
d mechanic!qualifie
Remove handlebar controls, clutch lever bracket and brake cylinder assy, then remove the
original handlebar. Loosen the clutch hose’s fixation at the top yoke
Mounting the adapter is done in
several steps:
1. Mount clamping devices (A)
loosely on the adapter plate
(B). Fit handle bar into the
clamping devices (A) and
tighten them with nickel-
plated M8x25 slightly so the
clamps can align to the
handle bar. Now tighten the
bolts from underneath the
plate with 25Nm / 18.44lbf ft
torque. Demount handle bar
at last.
2. Fix adapter brackets (C) on
the top yoke with M8x30 and
tighten them with 25Nm /
18.44lbf ft torque.
3. Fit pre-mounted adapter
(A&B) with nickel-plated
M8x25 and M8x45 on the
adapter brackets (C). Tighten
them with 25Nm / 18.44lbf ft
torque also.
LRecommended handlebar type: LSL-Fat Bar, high / Type XB3
Mount new handle bar into the clamps and adjust it. If the upper clamp is marked, the mark faces
forward. Tighten the handlebar clamps evenly with 25Nm / 18.44lbf ft torque.
Remount all handle bar controls and adjust them. Remember to check clearance between fairing
and handlebar and re-adjust handle bar, if necessary. Now you can drill bores to fix the handlebar
controls, if using a LSL-handlebar. Mount the left grip with suitable glue.
LIt was necessary to reduce the glove boxes opening angle to reach an ergonomic seating.
Take care to avoid damage to the glove boxes cover.
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Instructions for rerouting cables hoses and wiring harness:
Throttle cable: Routed as original. Check throttle cable for free movement on every steering
angle.
Brake hose: Mount attached brake hose
with new seal rings. Mind the mounting
instructions that are delivered with the brake
hose. Route as shown and fix it with
rubberized clamp and zinc-plated bolt
M6x12 at the bracket.
Clutch hose: The laying needs no change, but the
fixation at the top yoke needs to be moved upward. Fit
new bracket with nickel-plated bolt M6x12 on the top
yoke; then fix clutch hose with original bolt, attached
washer and self-locking nut M6 at the bracket.
Wiring harness: No changes, routed as original.
Make sure that no cable, hose or harness is
bended and stays tension-free over the whole
steering angle.
The conversion kit is now completely mounted. Always check local laws and your manufacturer’s
warranty conditions for using aftermarket parts on your bike!
Ride safe and have fun!
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LSL-Motorradtechnik GmbH • D-47809 Krefeld
www.lsl.eu
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