Kawasaki K53020-381 User Manual

Assembly Instructions

Description: Tachometer, Bar Clamp Model: Part-Number: K53020-381 Approximate

Assembly Time:

Before you begin installation, read through the installation instructions and check to be sure all parts are present.

If you are in doubt as to any part of the installation, please ask your authorized Kawasaki dealer to complete the installation. Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect installation.

Parts List Tools Required:

Seq. Part Number Description Qty.

VN900 B, D/ VN2000 E, F

30 min

K53020-381

2. 99-0615

Tachometer Assembly Quick Splice Connector, Blue

3. 99-0605 4” Zip ties 3

 Cross-point screwdriver

 Small flat blade screwdriver  Wire connector crimping pliers

 8mm Hex Socket 3/8“ drive  Ft.lb. torque wrench

22 Gauge Ring

4. TBD

Terminal

(VN2000 only)

Installation Instructions

Tachometer Installation Preparation

Parts Removal

• Refer to the Service manual for specific information in removing

the bar clamp components if further instruction is needed.

•

Remove the two screws holding the headlight assembly and carefully disconnect the 3-pin connector on the ba ck of the headlight reflector to remove the headlight, set it aside for now.

•

Remove the left side coil cover to expose the ignition coils.

•

Remove the four chrome handlebar clamp caps and bolts and the two clamps, being careful not to move the handlebars, see side note.

Install Tachometer

• Apply 2-stroke oil to the threads of the clamp bolts. Place the

tachometer onto the handlebar clamp area and reinstall the four bolts. Make sure the handlebar punch mark aligns with the lower mating surface of the bar clamp at the rear edge. Tighten the front clamp bolts first, and then the rear bolts.

Tighten the bolts to 34 Nm (25 Ft-lbs)

NOTE:

o There will be a small gap at the back of the clamp.

(Range minimum: 20 Ft lbs)

NOTICE

Punch mark aligned with

top surface

of lower

It is recommended that you have an assistant stabilize the handlebars at this point to prevent the handlebars from moving away from the original position and possibly causing damage to the fuel tank

clamp

• Route the wires down from the rearside of the tachometer

housing through the upper fork clamp wire and hose guide and into the rear of the headlight shell.

•

Connect the black and red tachometer wi res inside the headlight housing as indicated in the schematic below.

•

Route the green tachometer wire under the fuel tank and to the bottom of the front ignition coil. Remove the black wire connector from the front coil and install the green piggyback spade connector from the tachometer on the coil and reinsta ll the black coil wire onto the piggyback connector’s male spade terminal. Secure the wire with the supplied cable tie. Reinstall the chrome coil cover and tighten the set screw.

VN900 Coil Wire Connection VN2000 Coil Wire Connection

Coil

Black Coil

Wire

Be sure the ignition to the motorcycle is turned off prior to making any electrical connections

• Reconnect the 3-pin headlight plug onto the back of the headlight

and reinstall the headlight assembly onto the headlight shell, making sure to hook the top edge first and firmly snapping the bottom edge closed. Align the mounting holes and re-secure the headlight ri ng with the two cro s s - po int screws.

•

Start the engine and check the operation and lighting of the tachometer.

Tachometer Wires: Motorcycle Wires: Notes: Red Red / Blue Stripe (Turn signal side) Cut off supplied bullet connector, and attach with

Black Black / Yellow Stripe (accessory Green Black Coil Wire Green spade piggyback connector on to pin on coil

ground)

WIRE SCHEMATIC FOR VN900

supplied blue quick splice connector Insert male bullet connector into double female bullet connector inside headlight shell

where stock black wire was installed, reinstall black wire on to piggyback connector on coil

Tachometer Wires: Motorcycle Wires: Notes: Red Red / Blue Stripe (Turn signal side) Cut off supplied bullet connector, and attach with

Black Install on to acorn nut inside of

headlight shell

Green Black Coil Wire Green spade piggyback connector on to pin on coil

WIRE SCHEMATIC FOR VN2000

supplied blue quick splice connector Cut off supplied bullet connector and attach ring terminal to wire. Be sure paint is removed from headlight shell attachment point for proper ground.

where stock black wire was installed, reinstall black wire on to piggyback connector on coil

Care and Cleaning: Do not use abrasive cleaners; wash with mild soap and warm water.

Please check / adjust all scr ews in regular intervals.

NOTICE

Kawasaki Motors Corp. U.S.A., June 2009