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Kawasaki Concours 1400 Riser Installation Instructions

for Part # K405 (1.5 inch rise) and # 406 (2 inch rise)

Please read the installation instructions at least twice before attempting to install the risers.
It is recommended that a certified mechanic install this product.
Improper installation can cause serious injury or death.

 

 



1. Before installation we recommend that you cover the gas tank and fairing with a large towel to prevent scratches or damage during installation.
2. It is necessary to make a couple small modifications to the control cables before you install the GenMar risers. The hydraulic clutch line is held to the steering head by a metal routing bracket. This bracket needs to be unbolted and turned upside down. You will reuse the stock bolts and torque them to 8 ft. lbs. This will give the clutch line several inches of extra slack. Please refer to photo # 1 for a view of how the bracket should look after turning it upside down.
3. Next, you will need to remove the two plastic wire loom brackets on both sides of the lower triple-clamp. The brackets can be opened and the wires removed or the plastic brackets can be unsnapped from the triple-clamp. You will not re-install the wire loom brackets after installation because the majority of the slack in the wires will be used and the ties will not be needed. We are going to use nearly all of the slack in the stock brake hose. Therefore, it is necessary to loosen the front brake banjo fitting located at the bottom of the front brake master cylinder and rotate it forward approximately ½”. This will give the brake hose a more natural route and a little extra slack. Caution: You will only need to loosen the banjo fitting enough to rotate it forward. If the fitting is loosened too much, fluid can leak out. Do not pump the brake lever while the banjo fitting is loose. This can push the fluid out or suck air into the brake system. Re-tighten the banjo fitting to 16 ft. lbs. Please refer to photo #2 for a view of how the banjo fitting looks after it has been rotated.
4. Remove the two 6mm bolts that hold the square junction blocks for the hydraulic clutch and brake hoses to the top triple-clamp. Only one of the bolts will be re-used.
5. Remove the three 8mm bolts that hold the left handlebar to the triple-clamp. Raise the handlebar upward and slide the left side bar riser underneath the handlebar. The left handlebar riser has a threaded hole in the face and is marked “L”. Install three of the 8mm x 80mm bolts provided to attach the handlebar and riser to the triple clamp. Tighten the 8mm bolts to 16-18 ft. lbs. Now raise the square junction for the hydraulic clutch hose up to the threaded hole in the left riser and screw in one of the stock 6mm bolts previously removed. Torque to 8 ft. lbs.
6. Now install the right side riser. The right side riser does not have a threaded hole for the square brake junction. Instead, the bracket provided will be used to relocate the junction. Use the small 6mm x 10mm socket head bolt provided to mount the bracket to the triple-clamp where the square junction had been mounted before. Torque 6mm bolt to 8 ft. lbs. Now slide the square junction block over the stud on the GenMar bracket. Use 6mm nylock nut provided on the stud to attach the square junction to the bracket. Torque nut to 8 ft. lbs.
7. Start bike and turn handlebars full left and full right. If the motor races or decreases in RPMs, check that the cables are free and all necessary wire ties have been removed.
Please use the torque settings provided.
Over-tightening could compromise the strength and safety of the handlebars.


Improper installation voids any warranties and GenMar Mfg. Co., Inc. will assume no liability for injury or loss of property caused by improper installation of our risers.