Note: All assembly performed using Craftsman inch-pound and foot-pound torque wrenches, all screws, bolts, and nuts torqued as per kit instruction sheet, or Kawasaki Shop manual if not noted on instruction sheet.
1. Installed all the engine seals (foam rubber and/or silicone like pre-formed seals that go directly on the engine, and radiator shroud, and permit the radiator shroud to butt-up and seal tightly to the cylinder head) It all fits perfectly! This appears to have been engineered to really seal well, I'm impressed.
2. Electrical added (new fuse box with spare fuses for rear blower motor, new resistor in potted package to protect from weather, new wiring looms with new weather tight plugs, it all just plugs together!)
3. Assembled and mounted new radiator - seals tight to engine noted in #1 above
4. Performed search and destroy on all visible phillips head screws, replaced with button head hex screws and washers where used to hold plastic bits on, Much easier to remove. In an earlier post, I stated using SS button head hex screws, but had my mind changed when I went to purchase same, store wanted $1.10 EACH for M6x1/2 inch screws. Black screws were 67 cents each, so used those instead. Still, much better than Phillips head screws.
5. Mounted new rear blower and housing using included starter motor mounting screws and new chrome bracket ( That chrome bracket is absolutely beautiful, it reflects the cylinder head fins, really adds to the beauty of the engine. New screws are included with red thread sealer on them already, a nice feature!)
Stuff to be done Today, Saturday, 9/1/2012
6. Button it all up today, re-install muffler, pipe covers, right saddle bag, left side cover, right lower fairing cover, right passenger foot board. Remember folks, I have a trike kit on my bike, you may not have to remove all this stuff if you're still riding a 2 wheeler.
7. Add Engine Ice - decided to wait until today, so I can more clearly see if any leaks.
After project plans:
1. Buy new warmer jacket, because all that heat WILL be gone
2. Ride
hank
Glad for that. Don't see any obvious water leaks, let it run a minute or so more, than shut off. Fans ran until the temp dropped back to the 1/2 way mark. Put my hands in the vicinity of the exhaust pipes, detected a small amount of heat, but nothing like before. Don't feel that hurricane blast of volcanic heat from the radiator anymore. Heat from rear cylinder is now directed downward. Functions as advertised!, and, I am now a certified KAMS installation expert.
