Baron BIG AIR KIT SMOOTH Kawasaki Vulcan 2000 User Manual

BIG AIR KIT (BAK) - Kawasaki Vulcan 2000

Page: 1BA-2072-00/03/06/07/12/13/13B

Revision: 2.8 - 04/02/2010

INCLUDED IN THE KIT:
(1) Decorative BAK Cover
(1) Re-usable Performance Air Filter
(2) 1/4-28 x 1 13/16" Hex Bolts
(2) 1/4" Lock Washers
(2) 3/8"x 1.25" Aluminum Spacers
(1) Air Sensor Receiver Tube Pre-installed
(1) Rubber Washer Pre-installed
(1) E-clip Pre-installed

TOOLS REQUIRED:
3, 4 & 5 mm Allen Wrenches
10mm Open-End Wrench

CAUTION! We strongly recommend that a qualified technician install this kit
if you do not completely understand the instructions prior to the install. Have

the air/fuel mixture analyzed after installing this kit.

(1) O-Ring Pre-installed
(5) M6-1.0x16mm Flathead Screws
(1) Black BAK Backing Plate
(1) BAK Filter Raincoat
(2) 1/2" Rubber Caps
(2) 18 ga x 4" Wire Black
(2) Butt connectors
(1) Nylon Barbed Nipple (Pre-installed)

10 & 12mm Sockets
Phillips & Flat Screwdrivers

Pliers (Std. & Needle-nose)

Factory Service Manual

INSTRUCTIONS:
NOTE: We recommend the use of blue Loctite® on all fasteners and mounting hardware.

1. Remove fuel tank per Kawasaki service manual instructions. Please make note of the vent and drain hoses
connection points for later reconnection.

2. Remove stock air filter cover (4 screws), the stock air filter (1 screw) and then stock air box.

3. Unplug the air sensor and then disconnect the two hoses from back of air box.

4. Remove hoses going to top of each cylinder cover and cap off with supplied rubber plugs/caps, use the stock
clamps to lock in place.(You may shorten the plugs/caps if you like) It may be necessary to squeeze the clamps
closed slightly to get a good seal.

5. Remove the vent hoses that run to the black control valve, leave the control valve plugged to avoid FI error
lights on the dash.

6. Remove air sensor and rubber grommet from stock air box.

7. Install air sensor receiver tube in through the rear of the backing plate, place the rubber washer over the
portion of the tube that protrudes through the backing plate and insert the E-clip in the grove of the tube to
lock it in place. Insert the o-ring into the groove inside the tube. Insert/press the stock air sensor into the tube
from the rear of the backing plate. Make sure the sensor is seated & snug.

Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or

fitment may be required. Barons bears no responsibility on installation costs associated with this product.

© 2013 Barons Custom Accessories

5221 Oceanus Drive Huntington Beach, CA 92649 [phone] - Ph. [phone] - Fax www.baronscustom.com [e-mail]

Page: 2BA-2072-00/03/06/07/12/13/13B

BIG AIR KIT (BAK) - Kawasaki Vulcan 2000

8. Install BAK backing plate onto the throttle body securing it with the five M6 flathead screws supplied with
the kit. Use Blue Locktite® and tighten these screws firmly.

9. Connect crankcase vent hose to nylon nipple that came pre-installed on the backing plate.

10. Connect the electrical plug to sensor.

NOTE: 2008-2010 models have shortened the leads to this sensor which does not allow it to reach the new
sensor location. You must extend the wires by 4" so the connection can be made. Cut the wires about 1.5" from
the plug, strip the ends of the leads and the supplied 4" wires, splice the extensions into the lead wires. The
color of the wire we supplied is not important but you must bridge the connection between the same color wires.
Use the supplied butt connectors or you may solder these wires if you are equipped to do so.

11. Install the performance air filter into the groove of the backing plate, being sure the rubber seal fits/sits
firmly and fully in the groove in the backing plate.

TIP: Test fit the threads in the rear of the decorative cover by threading the two 1/4-28 x 1 13/16" hex bolts into
each of the two mounting holes to be sure they thread properly.

12. Insert the two supplied 1/4" lock washers onto and under the heads of the two 1/4-28 x 1 13/16" Hex Bolts
and insert the bolts through from the rear of the backing plate. Install the supplied 3/8" x 1.25" aluminum
spacers onto these bolts between the backing plate and the cover. Put Blue Locktite® in the last 1/4" of the
threads at end of the bolts.

NOTE: You may want to place masking tape across the hex heads to tape them to the backing plate so they do
not slide out during the next step.

13. Take the decorative BAK cover and set it up against the filter being sure to align and sit/fit the groove in the
cover with the rubber seal of the filter. When you are sure the filter seals into the grooves in the front and back
plates proceed to the next step.

14. Reach behind the cover and remove the tape from one hex bolt at a time and then blind align the bolts with
the threaded hole in the decorative cover plate carefully getting the threads started, then tighten them using a
3/8" wrench. Work slowly and be sure you have not cross threaded the bolts. Tighten the bolts firmly.

15. Reinstall fuel tank per service manual instructions.

16. We suggest/recommend you have a qualified and properly equipped service center test your air/fuel mixture
to determine whether your bike has an acceptable ratio (between 12 and 14 to 1). You may install a fuel
mapping device such as a Power Commander or TFI box according to instructions provided with that product,
if the air/fuel mixture ratio determines the need.

RAINCOAT: We supply a micron-mesh raincoat which does a very effective job of keeping moisture out of the
engine in rainy conditions. We suggest you install and run this all the time as a pre-filter as it does an excellent
job of keeping the filter clean reducing the filter maintenance. The raincoat is very easy to clean and re-install.

NOTE: Save all removed hoses/hardware for future re-installation if your state requires smog equipment
inspections.

Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or

fitment may be required. Barons bears no responsibility on installation costs associated with this product.

© 2013 Barons Custom Accessories

5221 Oceanus Drive Huntington Beach, CA 92649 [phone] - Ph. [phone] - Fax www.baronscustom.com [e-mail]