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Kawasaki KLE250C Assembly Instructions Manual

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2017 Kawasaki Heavy Industries, Ltd.
Page 1 of 7
Assembly Instructions
Model:
KLE250C, KLE300B/C
Description:
Pannier Case
Part Number:
99994-1094
Flat Rate Time(Hr):
0.6
Before you begin, read through these instructions and check that all parts are present.
Please note that Kawasaki cannot assume any responsibility for damage resulting from incorrect
installation.
Kawasaki recommends that all genuine accessories should be fitted by an authorized Kawasaki
dealer.
The following symbols indicate the information for proper installation and operation in this instruction.
NOTICE : NOTICE is used to address practices not related to personal injury.
NOTE
:
NOTE indicates information that may help or guide you in the operation or service of the
vehicle.
Indicates a procedural step or work to be done.
Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the
text of a NOTE.
Refer to the Service Manual for detailed procedures.
KLE250C: P/No.: 99924-1528-01
KLE300B/C: P/No.: 99924-1526-01
NOTICE
Install the left and right pannier cases simultaneous for stability.
Do not install the top case when the pannier cases are equipped.
Do not sit on the pannier case.
Do not carry loads of more than 3 kg (6.6 lb) in each pannier case.
Distribute the load equally on both sides of the motorcycle to minimize imbalance.
This pannier case is not perfect waterproof.
Parts List
No.
Part No.
Qty
Remark
1
23062-0965
1
2
23062-0966
1
3
57003-0172
1
4
57003-0173
1
5
92066-1184
2
6
92152-0332
8
7
92153-1267
8
M6 × 23 mm (0.91 in.)
8
92161-0927
8
9
92161-1910
4
10 Label
(Pannier Case Load Limit Warning)
56071-0723
2
ENGLISH
56071-0725
2
FRENCH
56071-0726
2
INDONESIAN
56071-0727
2
THAI
56071-0728
2
CHINESE
56071-0729
2
PORTUGUESE
56071-0730
2
JAPANESE
Page 2 of 7
Parts List
No.
Part No.
Qty
Remark
11 Label
(Pannier Case Notice)
56071-0758
2
ENGLISH
56071-0731
2
FRENCH
56071-0732
2
INDONESIAN
56071-0733
2
THAI
56071-0624
2
CHINESE
56071-0734
2
PORTUGUESE
56071-0735
2
JAPANESE
12
21007-0661
2
13
13272-2466
8
14
13272-2467
8
15
13272-2468
8
16
92145-1801
16
17
92172-1229
4
18
13272-2465
2
19
14093-0675
2
20
92210-1605
2
Page 3 of 7
Installation Instructions
(Left Pannier Case)
Install the plug [5] to the left pannier case bracket [1].
Remove the grab rail bolts [A].
Install the left pannier case bracket [1].
Tighten the grab rail bolts [A].
Torque – Grab Rail Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Install the following parts to the left pannier case [3].
Dampers [8]
Collars [6]
Plugs [9]
Install the left pannier case [3] to the left pannier case
bracket [1].
Tighten the bolts [7].
Page 4 of 7
When required, apply the labels over the pictograph labels
on the pannier cases.
Wipe off any oil or grease from the pictograph labels.
Peel each label off the backing sheet and apply it over the
pictograph labels.
Pannier Case Load Limit Warning [10]
Pannier Case Notice [11]
(One Key System Assembly Procedure)
○ Using a combination of tumblers in this kit allows the lock
rotor to be assembled to fit the existing ignition key.
○ The tumblers of 3 types are identified by the number
punched on the tumbler.
Guideline for selecting correct Key combination
Tumbler No.1 [A]
Tumbler No.2 [B]
Tumbler No.3 [C]
Step 1
Install 4 springs [16] and 4 tumblers [13] [14] [15] to the
grooves [A] of the rotor [12]. Press each tumbler into its
groove until it fully seats.
NOTE
○ The projection of the tumbler should sit over the spring.
Step 2
Lightly hold the tumblers [A] in the rotor [12] and insert the
ignition key [B].
NOTE
○ If the tumblers are not held in place the tumblers or
springs may become dislodged.
Page 5 of 7
Step 3
If the tumbler [A] is the correct one for the cut in the key it will sit level with the rotor [12] once the ignition
key [E] is inserted.
Incorrect: [B] Projecting high (upper or lower of rotor)
Incorrect: [C] Projecting low (upper or lower of rotor)
Correct: [D] Level with the rotor
If any of the tumblers project out of the rotor, go to “Step 4.”
If all tumblers sit flush with the rotor it is correct. Go to “Step 5.”
Step 4
While lightly holding the tumblers in the rotor, remove the ignition key.
NOTE
○ If the tumblers are not held in place the tumblers or springs may become dislodged.
Replace any projecting tumbler(s) with tumbler(s) from another bag and repeat steps 2, 3, and 4 again
until all tumblers are level with the rotor.
Step 5
Apply oil (WD-40 or equivalent) [A] on the rotor [12] as
shown.
Step 6
Apply grease ( Mechapower : EPS no.1 or equivalent) on
the end [A] of the rotor [12] as shown.
Page 6 of 7
Step 7
Insert the rotor [12] into the rotor case [19].
NOTE
○ Ensure that there is rotation of 90 degree when the rotor
is rotated inside the rotor case.
Step 8
Hold the rotor case with the suitable tool [A].
Apply a non-permanent locking agent (Loctite 263 or
equivalent) to the threads of screws [17].
Install the hook [18] to the rotor so that it is positioned as
shown, and tighten the screws.
Torque – Screws: 0.5 N·m (0.05 kgf·m, 4.4 in·lb)
NOTICE
Do not reuse the rotor.
Step 9
Install the rotor case [19] to the pannier case so that the
mark [A] faces leftward.
P/No. 99958-0398
Page 7 of 7
Step 10
Install the locknut [20] so that the flat face side [A] faces
inward, and tighten it.
Torque – Locknut: 3.0 N·m (0.31 kgf·m, 27 in·lb)
After installing the rotor case, make sure that the lock
operates correctly and when removing the ignition key the
rotor is secure in the pannier case.
NOTE
○ When closing and opening the pannier case lid [A], turn
the ignition key [B] while pushing the pannier case lid
downward [C].
(Right Pannier Case)
Install the right pannier case in the same way of the left
pannier case.
Basic Torque for General Fasteners
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for
use with dry solvent-cleaned threads.
Threads dia. (mm)
Torque
N·m
kgf·m
ft·lb
5
3.4 ∼ 4.9
0.35 ∼ 0.50
30 ∼ 43 in·lb
6
5.9 ∼ 7.8
0.60 ∼ 0.80
52 ∼ 69 in·lb
8
14 ∼ 19
1.4 ∼ 1.9
10 ∼ 13.5
10
25 ∼ 34
2.6 ∼ 3.5
19 ∼ 25
12
44 ∼ 61
4.5 ∼ 6.2
33 ∼ 45
14
73 ∼ 98
7.4 ∼ 10.0
54 ∼ 72
16
115 ∼ 155
11.5 ∼ 16.0
83 ∼ 115
18
165 ∼ 225
17.0 ∼ 23.0
125 ∼ 165
20
225 ∼ 325
23.0 ∼ 33.0
165 ∼ 240
Check tightness of all fasteners in regular interval. Retighten loose fasteners.
/