Assembly Instructions - Jet Ski · 14 Defrost Vent Housing 2 MP605-01 15 Face Vent Housing 2...

© 2019 Kawasaki Motors Corp. USA of 21

Assembly Instructions

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.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

NOTICE is used to address practices not related to personal injury.

● Indicates a procedural step or work to be done.

Model: Teryx KRX

Description: Heater Kit

Part Number: 99994-1306

Assembly Time: 3 Hours

DANGER

NOTICE

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Parts List

No. Component Name Qty Remark

01 Heater Assembly 1

02 Thermostat Performance Valve 1

03 Y-Fitting 1 HW900-08

04 Rubber Grommet 2 GC-602

05 Large Hose Clamp 4

06 Small Hose Clamp 2

07 Inlet Hose Kit 1

08 Passenger Side Face Duct 1 MP605-06

09 Driver Side Face Duct 1 MP605-05

10 Driver Side Defrost Duct Upper 1 MP605-08

11 Driver Side Defrost Duct Lower 1 MP605-07

12 Passenger Side Defrost Duct 1 MP605-09

13 Floor Duct Assembly 1 HSK-605F

14 Defrost Vent Housing 2 MP605-01

15 Face Vent Housing 2 MP605-02

16 Louver Assy 4

17 Vent Retaining Ring 4 MP605-03

18 Mode Selection Switch 1

19 Control Panel 1

20 Switch Face Plate 1

21 Switch Knob (D-Shaft) 1

22 Switch Knob (Spline Shaft) 1

23 Cable Tie 2

24 Air Bleed Hose 1

25 M6 Self-Tapping Screw 2

26 M6 X 1.00- 20 Machine Screw 2

Recommended Tools

Tool Type Size

Socket 8mm, 10mm, 19mm

Screwdriver Phillips #3

Drill Bit 1/8” Pilot Bit

Hole Saw 1.250”

Cutters Zip Tie Cutter, Utility Knife

Pliers Needle nose

Specialty Tools Push Rivet Removal Pliers, Radiator Hose Clamps X4, Radiator Hose Cutters

Terms

Term Definition

Nyloc Nylon insert locking nut

Pressure Side Refers to side after water pump - driver side coolant line from engine to radiator

Suction Side Refers to side before water pump - coolant line from radiator to engine (return)

Inlet Radiator Hose

Radiator hose from engine to radiator

Outlet Radiator Hose

Radiator hose from radiator to engine

Parts Photo

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Installation Overview Diagram

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Add balloons on exploded view of vent assemblies and control panel.

Installation Instructions

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• Park the vehicle on level ground, set the parking brake, turn off the ignition switch.

• Disconnect the negative battery terminal.

• Let vehicle cool.

• Pull grab bar plunger down and remove grab bar.

• Remove R-clip using needle nose pliers and remove passenger grab bar plunger assembly.

• Remove 6 plastic rivets and 2 screws. Disconnect all electrical connections and remove center dash panel.

DANGER

Failure to disconnect battery may run the risk

of electrocution.


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• Remove steering wheel center cover.

• Remove steering wheel nut using 19mm socket. Remove washer and steering wheel.

• Remove 4 bolts using 10mm socket from sides and back of meter. Remove 3 screws from back cover. Remove cover and disconnect meter connection.

• Remove 7 plastic rivets and 3 screws. Remove the ignition switch nut. Disconnect all electrical connections and remove driver side dash panel.


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• Remove glove box cover.

• Remove 7 plastic rivets and 3 screws. Disconnect 12VDC accessory outlet connection and remove passenger side dash panel.

• Remove 4 plastic rivets and remove access panel.

• Following scribe lines on center console, locate center of scribe line circles, and drill a pilot hole using an 1/8” drill bit.

• Using a 1.250” hole saw, cut through center console referencing the pilot holes. Deburr cut holes and push back insulation on underside of center console.


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• Put a thin layer of silicone lubricant on O-ring of inlet hose kit (07). Install into bottom of electronic temperature control unit and secure with retaining clip.

• Put a thin layer of silicone lubricant on both inlet and outlet heater hoses. Install rubber grommets (04) on each hose.

Video – Hose Kit + Clip https://ktkh.pcione.com/hose-kit

• Disconnect electronic throttle control connection on driver side. Refer to image for circled location.

• Cut and remove harness strap tie band to release wire harness. This strap tie band will be replaced during the wire harness installation.

• Reposition wiring harness toward operator side of crossbar.


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• Install heater through passenger side under frame support. Lift heater assembly up toward firewall and install floor duct assembly (13).

Video – Heater Placement https://ktkh.pcione.com/heater-assembly

• Set heater into position while routing heater hoses through center console holes.

• Seat rubber grommets (04) into center console holes that were previously cut.

• Install 2 M6 self-tapping screw (25) through rear bracket into formed frame holes. Do not fully tighten.

• Install 2 M6x1.0-20mm machine screw (26) through front bracket into threaded frame holes. Do not fully tighten.


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• Locate the previously installed heater hoses through the access panel on the passenger side of center console. Mark a 25mm section of the radiator outlet hose and 50mm of the inlet radiator hose. Cut marks should be centered around heater hoses as shown.

NOTE o Inlet radiator hose is from engine to radiator.

Outlet radiator hose is from radiator to engine.

• Clamp both inlet and outlet radiator hoses, towards the rear of side access panel.

• Clamp outlet radiator hose where it enters cab, in front of the firewall.

• Clamp inlet radiator hose where it exits cab, in front of the firewall.


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• Remove the marked sections the inlet and outlet radiator hoses.

NOTE o Engine coolant will leak from hose between

clamps. Use a container under vehicle to catch coolant.

• Install Y-fitting (03) in outlet heater hose, on driver side of heater, and secure with small hose clamp (06). Install Y-fitting (03) in outlet radiator hose and secure with 2 large hose clamps (05). Torque – Large hose clamp (05): 4.0 N•m (0.41

kgf•m, 2.95 ft•lb) Small hose clamp (06): 4.0 N•m (0.41

kgf•m, 2.95 ft•lb)

• Install thermostat performance valve (02) in inlet hose kit (07) and secure with small hose clamp (06). Install thermostat performance valve (02) in inlet radiator hose and secure with 2 large hose clamps (05). Torque – Large hose clamp (05): 4.0 N•m (0.41

kgf•m, 2.95 ft•lb) Small hose clamp (06): 4.0 N•m (0.41


• Remove 4 clamps from radiator hoses and verify there are no leaks.

• Tighten 2 M6 self-tapping screw (25) through rear bracket.

• Tighten 2 M6x1.0-20mm machine screw (26) through front bracket.


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• Connect electronic throttle control connection. Refer to image for circled location.

• Connect red positive wire harness to positive terminal of terminal block. Connect black negative wire harness to negative terminal of terminal block

• Secure heater harness and vehicle harness to frame with cable tie (23). Be sure to leave enough slack in the harness between the frame and dashboard to install the control panel and toggle switch.

• Following the scribe lines, on bottom side of dash, cut out the defrost rectangle vent holes in 2 places.

NOTE o Cut on the inside of scribe lines toward the

center of rectangle.


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• Deburr all cut edges

• Following the scribe lines, on back side of dash, cut out the face rectangle vent holes in 2 places.

NOTE o Cut on the inside of scribe lines toward the

center of rectangle.


• On the center dashboard, cut 2 bottom row left switch locations. Refer to next picture for switch hole locations.

NOTE o Holes must be cut to the outside edge of scribe

lines but not into textured area. This is important to ensure correct fitment of the control panel.


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• Connect 12VDC accessory outlet connection and assemble passenger side dash panel using 7 plastic rivets and 3 screws.

• Install ignition switch and tighten nut. Connect all electrical connections and assemble driver side dash panel using 7 plastic rivets and 3 screws.

• Snap louver assembly (16) into face vent housing (15).

• Snap face vent housing (15) into passenger side face duct (08).

• Slide passenger side face duct (08) through face vent hole in passenger side dash panel.

• Slide vent retaining ring (17) onto passenger side face duct (08). Be sure to put the side labeled “DASH SIDE” toward the back side of dash.


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• Snap face vent housing (15) into face vent hole in passenger side dash panel.

• Snap vent retaining ring (17) onto face vent housing (15) tight against the back side of dash.

• Snap passenger side face duct (08) onto passenger side output on top of heater.

• Snap louver assembly (16) into face vent housing (15).

• Snap face vent housing (15) into driver side face duct (09).

• Slide driver side face duct (09) through face vent hole in driver side dash panel.

• Slide vent retaining ring (17) onto driver side face duct (09). Be sure to put the side labeled “DASH SIDE” toward the back side of dash.

• Snap face vent housing (15) into face vent hole in driver side dash panel.

• Snap vent retaining ring (17) onto face vent housing (15) tight against the back side of dash.

• Snap driver side face duct (09) onto driver side output on top of heater.

• Snap louver assembly (16) into defrost vent housing (14).

• Snap defrost vent housing (14) into passenger side defrost duct (12).

• Slide passenger side defrost duct (12) through defrost vent hole in passenger side dash panel.

• Slide vent retaining ring (17) onto passenger side defrost duct (12). Be sure to put the side labeled “DASH SIDE” toward the bottom side of dash.


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• Snap defrost vent housing (14) into defrost vent hole in passenger side dash panel.

• Snap vent retaining ring (17) onto defrost vent housing (14) tight against the bottom side of dash.

• Snap passenger side defrost duct (12) onto passenger side output of floor duct assembly (13).

• Snap louver assembly (16) into defrost vent housing (14).

• Snap defrost vent housing (14) into driver side defrost duct upper (10).

• Slide driver side defrost duct upper (10) through defrost vent hole in driver side dash panel.

• Slide vent retaining ring (17) onto driver side defrost duct upper (10). Be sure to put the side labeled “DASH SIDE” toward the bottom side of dash.

• Snap defrost vent housing (14) into defrost vent hole in driver side dash panel.

• Snap vent retaining ring (17) onto defrost vent housing (14) tight against the bottom side of dash.

• Feed driver side defrost duct lower (11) through hole in rear bracket and snap into driver side defrost duct upper (10).

• Snap driver side defrost duct lower (11) onto driver side output of floor duct assembly (13).


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• Remove hood and fill radiator as described in service manual. Be sure to tighten radiator cap.

• Locate the air bleed port on heater assembly (01). Refer to image for circled location.

• Connect the air bleed hose (24) to the air bleed port by pulling back on the quick release sleeve.

• Connect the hose end to Mity Vac or equivalent and pump the air out of the system until you see NO AIR BUBBLES.

• Connect meter connection and assemble 3 screws on back cover. Assemble meter using 4 bolts with 10mm socket on sides and back of meter.


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• Assemble steering wheel and washer. Assemble steering wheel nut using 19mm socket. Torque – Steering wheel nut: 52.5 N•m (5.35


• Assemble steering wheel center cover.

• Assemble passenger grab bar plunger assembly using R-Clip and needle nose pliers.


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• Assemble glove box cover.

• Install control panel and toggle switch on 2 bottom row left switch locations of center console. Refer to image and video for further information.

NOTE o The switch, with d-shaft, is on top.

NOTE

o The spline shaft switch on bottom can be adjusted for tighter fitment by slightly opening center gap with small flat head screwdriver.

Video – Installing Control Panel https://ktkh.pcione.com/controls

• Plug in 3 connectors while assembling the center dash panel.

• Pull grab bar plunger down and assemble grab bar.


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• Connect the negative battery terminal

• Start the vehicle and turn on heater to “High Heat”.

• Verify there are no leaks.

• Assemble access panel using 4 plastic rivets.

• Heating System Operation:

• System Off – Turn fan speed control fully counterclockwise and/or mode selection switch to middle position.

• Adjust Fan Speed – Turn fan speed control clockwise for low, medium, and high speed.

• Adjust Temperature – Turn temperature control clockwise from cold (BLUE) to hot (RED).

• Mode Selection Switch – Press face vent mode for face vents only. Press defrost/floor vent mode for defrost and floor. Middle position turns system off.

NOTE

o Never completely close face vents and never close both defrost and floor at the same time. This system uses the opposite vent mode for the intake of the selected vent mode.

Enjoy your Kawasaki Genuine Accessory

Service Parts

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No. Component Name Service Part No. Qty

1 Heater Assembly HSK-605A 1

2 Motor w/ Fan Blade Assembly HSK-602B 1

3 Scroll Blower w/ Housing HSK-501B 1

4 Electronic Temperature Control Assembly HSK-605K 1

5 Inlet Hose Kit HSK-605L 1

6 Small Hose Clamp HCL-601 2

7 Thermostat Performance Valve TA-605 1

8 Y-Fitting HW900-08 1

9 Large Hose Clamp HCL-401-2 4

10 Air Bleed Hose AB-601 1

11 Vent Assembly, Dash HSK-605D 1

12 Vent Assembly, Floor HSK-605F 1

13 Vent Assembly, Defrost HSK-605E 1

14 Control Panel HSK-605C 1

15 Mode Selection Switch HA-S04 1

16 Wire Harness Assembly HSK-605G 1

17 Resistor RF-001 1

18 Hardware Kit HSK-605H 1

P/N 99994-1306 REV 01

Assembly Instructions - Jet Ski · 14 Defrost Vent Housing 2 MP605-01 15 Face Vent Housing 2...

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