Superatv Kawasaki teryx4 power steering kit User manual

INSTALLATION INSTRUCTIONS

(Kit Contents continue on following page)

Thank You

For Choosing

Power Steering Kit

for Kawasaki Teryx4™

Read instructions and view illustrations before beginning.

Need help with your installation?

www.superatv.com

8:00am - 9:00pm EST M-Th

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9:00am - 2:00pm EST Saturday

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1-855-743-3427

2753 Michigan Road • Madison, Indiana 47250 • 855-743-3427

M8 x 20mm Lg. FHCS3x

2x M6 x 16mm Lg. HHCS

-includes washers (not shown)

M6 Flat Washer4x

M6 Nylock Nut2x

2x M6 x 20mm Lg. HHCS

M8 x 16mm Lg. FHCS2x

(PS-K-TRX4-001 Upper Shaft)

(PS-K-TRX4 Upper Shaft)

Item Description

D Upper Shaft

E Lower Shaft

F Motor Bracket

H Wiring Connectors

M ECU Bracket

2IN-PS-K-TRX4 / IN-PS-K-TRX4-001

(Kit Contents continued)

Item Description

A ECU

B Wiring Harness

C Motor

Push in....

Seat

*Connections

- Before installing, ensure that all Gaskets in electrical connections are properly seated.

- If Gaskets are not seated use a Flathead Screwdriver to seat.

....Seat

3IN-PS-K-TRX4 / IN-PS-K-TRX4-001

Remove Dash Screws

Fig. 1

Remove

(Driver Side) Fig. 1a

Disconnect Wire Harness’ from Dash

Front

Fig. 1b

(removal illustrations continue on following pages)

Removal: Keep all stock hardware.

1. Remove Screws and Plastic Rivets from Dash. Disconnect Wire Harness’ and remove hardware from

Driver Side of Roll Cage; remove Dash. See Figs. 1 - 1c.

2. Remove hardware from Upper and Lower Shafts. See Figs. 2 - 2a.

3. Remove (4) Bolts from stock Mounting Bracket. See Fig. 3.

4. Remove Upper Shaft, Mounting Bracket, and Lower Shaft from machine. See Figs. 4 - 4a.

Remove all

Plastic Rivets

Disconnect

Fig. 1c

Connection no longer used.

Secure in a appropriate location.

4IN-PS-K-TRX4 / IN-PS-K-TRX4-001

(removal illustrations continued)

(Driver Side)

Front

Remove hardware

Rack and Pinion

Lower Shaft

Fig. 2

Remove hardware

Upper Shaft

Fig. 2a

Remove Lower Shaft

Fig. 4a

Remove Upper Shaft

Fig. 4

Remove

Fig. 3

Mounting Bracket

5IN-PS-K-TRX4 / IN-PS-K-TRX4-001 (illustrations continue on following pages)

Installation: Do not tighten hardware completely unless noted.

1. Install Motor Bracket (F) to Motor (C) with M8-1.25 x 20mm Lg. FHCS. See Fig. 1.

2. Install ECU (A) to ECU Bracket (M) with M6-1.0 x 16mm Lg. HHCS; tighten hardware. See Fig. 2.

3. Install Lower Shaft (E) to Rack and Pinion with supplied hardware. See Figs. 3 - 3a.

4. Install Motor (C) to Lower Shaft (E) with supplied hardware. See Fig. 4.

5. Install Upper Shaft (D) to stock Upper Steering Shaft with supplied hardware. See Figs. 5 - 5a.

6. Join Upper Shaft (D) to Motor (C) with supplied hardware. See Fig. 5a.

7. Locate (2) mounting locations, as shown in Fig. 6, and install Motor Bracket (F) with M8-1.25 x 16mm

Lg. FHCS. See Fig. 6.

8. Install ECU Bracket (M) to Motor Bracket (F) with M6-1.0 x 20mm Lg. HHCS, M6 Flat Washers, and

M6-1.0 Nylock Nuts. See Fig. 6.

9. Plug Wiring Harness (B) into ECU (A) and connect wiring. See Wiring Details, page 8.

10.Ensure no components are binding, rubbing, or causing interference and tighten all hardware

completely.

11. Reinstall necessary compents uninstalled during “Removal”.

Fig. 1

M8 x 20mm

Fig. 2

M6 x 16mm

Fig. 3

(Driver Side)

Rack and Pinion

Front

supplied hardware

Fig. 3a

6IN-PS-K-TRX4 / IN-PS-K-TRX4-001

220 Motor

to Rack and Pinion

7IN-PS-K-TRX4 / IN-PS-K-TRX4-001

Fig. 4

supplied hardware

Fig. 5a

(Driver Side)

Insert through here

Fig. 5

8IN-PS-K-TRX4 / IN-PS-K-TRX4-001

Bracket Mounting, Fig. 6

Passenger Driver

Orientation

Bracket Mounting Locations

M8 x 16mm

M6 Nut

M6 Washer

M6 x 20mm

9IN-PS-K-TRX4 / IN-PS-K-TRX4-001

Plug Function

A Torque Sensor

B Switched 12V Source

C Power

D Motor Diagnostic Light

Secure Diagnostic Light

in a visible location.

When activated, Diagnostic Light will ash (1) time for about

(1) second before turning off indicating proper function.

Should different patterns occur, contact SuperATV.

Wiring Details

Negative (-)

To Switched 12V Source

(See 12V Source Connection Details)

(Black)

(White)

(Red)

B C

Positive (+)

Battery Connections

Battery

(Passenger Side) Front

Black = Negative (-)

Red = Positive (+)

Soldering connection is recommended however, installer

may use other forms of connecting.

1. Locate Connector shown in Fig. A.

2. Connect White Wire from Wire Harness (B) to Tan with

Yellow Stripe and Silver Dashed wire. Scotch Lock

(included) or solder. See Fig. B.

Switched 12V Source Connection Details

(Driver Side)

White Wire, Switched 12V Source

from Wire Harness (B)

Scotch Lock

Tan w/Yellow Stripe and

Silver Dashed Wire

Fig. A

Fig. B

10IN-PS-K-TRX4 / IN-PS-K-TRX4-001

Liability Statement

SuperATV’s®products are designed to best fit user’s ATV/UTV under stock conditions. Adding, modifying, or fabricating any factory or aftermarket parts will void any warranty

provided by SuperATV®and is not recommended. SuperATV’s® products could interfere with other aftermarket accessories. If user has aftermarket products on machine, contact

SuperATV®to verify that they will work together.

Although SuperATV®has thousands of satisfied customers, user should be aware that installing lift kits, long travel, or suspension kits, tires, etc. will change the ride of machine

and may increase maintenance and part wear. Operating any off-road machine while, or after, consuming alcohol and/or drugs increases risk of bodily harm or death. No

warranty or representation is made as to this product’s ability to protect user from severe injury or death. SuperATV®urges operators and occupants to wear a helmet and

appropriate riding gear at all times.

By purchasing and installing SuperATV®products, user agrees that should damages occur, SuperATV®will not be held responsible for loss of time, use, labor fees, replacement

parts, or freight charges. SuperATV®, nor any 3rd party, will not be held responsible for any direct, indirect, incidental, special, or consequential damages that result from any

product purchased from SuperATV®. The total liability of seller to user for all damages, losses, and causes of action, if any, shall not exceed the total purchase price paid for the

product that gave rise to the claim.

SuperATV®will warranty only parts provided by SuperATV®. Any damage or problems with OEM housings, bearings, seals, or other manufacturers’ products will not be covered

by SuperATV®. SuperATV®parts and products are not warrantied if item was not installed properly, misused, or modified.

Installing, adding, modifying, or fabricating any factory or aftermarket product to your ATV/UTV may violate certain local, state, and federal laws. Be advised that laws vary

depending on town, city, county, state, etc. Use of certain products on public streets, roads, or highways may be in violation law. The Buyer is solely and exclusively legally and

personally responsible for any violation of the law by the installation or use of the product. You must abide by all local, state, and federal laws, including but not limited to vehicle

safety, traffic laws, and ordinances. It is your responsibility to know the laws and how they apply to you.

The Buyer is responsible to fully understand the capability and limitations of his/her vehicle according to manufacturer specifications, warnings and instructions and agrees to

hold SuperATV®harmless from any damage resulting from failure to adhere to such specifications, warnings and/ or instructions. The Buyer is also responsible to obey all

applicable federal, state, and local laws and ordinances when operating his/her vehicle while using this product, and the Buyer agrees to hold SuperATV®harmless from any

violation thereof.

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