Thank You For Choosing. INSTALLATION INSTRUCTIONS Power Steering Kit: for Suzuki KingQuad. (kit contents continue on following page)
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1 2753 Michigan Road Madison, Indiana INSTALLATION INSTRUCTIONS Power Steering Kit: for Suzuki KingQuad Item F G H M Description ECU racket Lower Shaft Upper Shaft Mounting racket Wiring Connectors Kit F M G H (kit contents continue on following page) Need help with your installation? sales@superatv.com :00am - 9:00pm EST M-Th 8:00am - 7:00pm EST Friday 9:00am - 2:00pm EST Saturday Read instructions and view illustrations before beginning. Thank You For Choosing 2013 SuperATV.com. All Rights Reserved. Rev 2/16/2018
2 M6-1.0 x 16mm Lg. HHCS -includes washers (not shown) 1x M6-1.0 Nylock Nut M x 25mm Lg. HHCS M6 Washer 1x M6-1.0 x 20mm Lg. HHCS M Nylock Nut 3x M x 20mm Lg. FHCS M8 Washer *Connections - efore installing, ensure that all Gaskets in electrical connections are properly seated. - If Gaskets are not seated use a Flathead Screwdriver to seat. Item J K L Description ECU Motor Wiring Harness J* Seat K* L* to Rack and Pinion Seat 2
3 Liability Statement SuperATV s products are designed to best fit user s ATV/UTV under stock conditions. Adding, modifying, or fabricating any factory or aftermarket parts will void any warranty provided by SuperATV and is not recommended. SuperATV s products could interfere with other aftermarket accessories. If user has aftermarket products on machine, contact SuperATV to verify that they will work together. Although SuperATV has thousands of satisfied customers, user should be aware that installing lift kits, long travel, or suspension kits, tires, etc. will change the ride of machine and may increase maintenance and part wear. Operating any off-road machine while, or after, consuming alcohol and/or drugs increases risk of bodily harm or death. No warranty or representation is made as to this product s ability to protect user from severe injury or death. SuperATV urges operators and occupants to wear a helmet and appropriate riding gear at all times. y purchasing and installing SuperATV products, user agrees that should damages occur, SuperATV will not be held responsible for loss of time, use, labor fees, replacement parts, or freight charges. SuperATV, nor any 3rd party, will not be held responsible for any direct, indirect, incidental, special, or consequential damages that result from any product purchased from SuperATV. The total liability of seller to user for all damages, losses, and causes of action, if any, shall not exceed the total purchase price paid for the product that gave rise to the claim. SuperATV will warranty only parts provided by SuperATV. Any damage or problems with OEM housings, bearings, seals, or other manufacturers products will not be covered by SuperATV. SuperATV parts and products are not warrantied if item was not installed properly, misused, or modified. Installing, adding, modifying, or fabricating any factory or aftermarket product to your ATV/UTV may violate certain local, state, and federal laws. e advised that laws vary depending on town, city, county, state, etc. Use of certain products on public streets, roads, or highways may be in violation law. The uyer is solely and exclusively legally and personally responsible for any violation of the law by the installation or use of the product. You must abide by all local, state, and federal laws, including but not limited to vehicle safety, traffic laws, and ordinances. It is your responsibility to know the laws and how they apply to you. The uyer is responsible to fully understand the capability and limitations of his/her vehicle according to manufacturer specifications, warnings and instructions and agrees to hold SuperATV harmless from any damage resulting from failure to adhere to such specifications, warnings and/ or instructions. The uyer is also responsible to obey all applicable federal, state, and local laws and ordinances when operating his/her vehicle while using this product, and the uyer agrees to hold SuperATV harmless from any violation thereof. Power Steering will provide multiple improvements to your machine. After installation, it is highly recommend to take time and learn your machines new handling characteristics and feel. Key Recommendations: 1. Power Steering enefits will be noticed as soon as machine is moving. 2. Handlebar will have more noticeable deflection while at rest. As a result of speed sensitive operation, this is normal. 3. Check steering sensitivity at multiple speeds to best understand new handling characteristics and feel. 4. Without Throttle input, turning Handlebar back and forth unnecessarily is not recommended. This action is very hard on remaining stock steering components, Tie Rod Ends, and Power Steering unit. Like all SuperATV products, Power Steering kits were designed with riders in mind. For reference, photographing of removal process is highly recommended due to amount of components being removed from machine. Removal: Keep all components removed from machine. 1. Raise front of machine, secure with jack stands and remove Wheels. Removing Left Shock may help. 2. Remove Seat and Side Panels. See Fig Remove Handlebar Cover and Speedometer. See Fig Remove Carrier and Fender. See Fig Remove Steering Shaft Holder (including Dust Shields), and Hose Guide from Frame. See Fig Remove Tie Rods from Steering Shaft. See Figs. 5-5a. 7. Remove Cotter Pin, Nut, and Nut from Steering Shaft. See Figs. 5-5a. 8. Unbolt Handlebar and lay out of way. 9. Remove Steering Shaft. See Fig. 6. (removal illustrations on following page) 3
4 Remove Side Covers (Right and Left) Fig. 5 Remove Seat Remove Fig. 1 Remove Handle Cover and Speedometer Remove Pin, Nut, and Washer Fig. 5a Steering Shaft Fig. 2 Fig. 6 Remove Fender Remove Steering Shaft Remove Remove Carrier () Fig. 3 Fig. 4 4
5 Installation: Do not tighten hardware unless noted. 1. Install Lower Shaft (F) to stock location. Secure with stock hardware. See Figs. 1-1b. - Reinstall Tie Rods with stock hardware. See Fig. 1b. 2. Install Motor (K) onto Lower Shaft (F). Secure with provided hardware. See Fig Install Mounting racket (H) to Motor (K) with M x 20mm Lg. FHCS. See Fig Locate (2) holes in Frame; secure Mounting racket (H) with M x 25mm Lg. HHCS, M8 Flat Washers, and M Nylock Nuts. See Fig From top of machine, install Upper Shaft (G) to Motor (K) and secure with provided hardware. See Fig Install Upper Shaft (G), stock Steering Shaft Holder (including Dust Shields), and Hose Guide to Frame with stock hardware. See Fig. 4a. 5. Use stock hardware to reinstall Handlebar to Upper Shaft (G). See Fig Install ECU racket () to Frame with M6-1.0 x 20mm Lg. HHCS, M6 Flat Washers, and M6-1.0 Nylock Nut. See Fig Install ECU (J) to ECU racket () with M6-1.0 x 16mm Lg. HHCS. See Fig. 6. Plug in Wire Harness (L) but do not wire. 8. Make wire connections. See Wiring Details pages Handlebar should be inline with Tie Rods before tightening hardware. Lift Handlebar up and off of Motor (K) and realign if not. 9. Tighten all hardware completely. 10. Reverse steps taken during Removal and reinstall necessary components. Fig. 1 Install Lower Shaft Assembly (F) here. Fig. 1a Fig. 1b F Reinstall Tie Rods with stock hardware. F Install with stock hardware. (installation illustrations continue on following pages) 5
6 3x Fig. 2 (Right Side) M8 x 20mm H K F provided hardware 6
7 Mounting racket (H), Fig. 3 H Mounting Hole Frame K Mounting Hole (Right Side) H M8 x 25mm (Right Side) M8 Washer M8 Nut 7
8 Fig. 4 G provided hardware K PARTS REFERENCE Item Description Qty ECU racket 1 F Lower Shaft 1 G Upper Shaft 1 H Mounting racket 1 M Wiring Connectors Kit 1 Fig. 4a G Apply grease when reinstalling Stock Components Fig. 5 Stock G 8
9 M6 x 20mm Control Module Mounting, Fig. 6 M6 Washer M6 Nut Mounting Location J J M6 x 16mm 9
10 Wiring Details (White) (lack) (Red) To Switched 12V Source (See 12V Source Connection Details) To attery, Negative (-) To attery, Positive (+) Switched 12V Source Connection Details Wire Harness K J Handlebar Fig. A (Right) L White Wire, Switched 12V Source from Wire Harness (L) Plug A C D J A Function Torque Sensor Switched 12V Source Power Motor When activated, Diagnostic Light will flash (1) time for about (1) second before turning off indicating proper function. Should different patterns occur, contact SuperATV. Secure Diagnostic Light in a visible location. C D Diagnostic Light ullet Connector or Scotch Lock Orange Wire Fig. Soldering connection is recommended however, installer may use other forms of connecting. 1. Locate Orange Wire from Wire Harness shown in Fig. A. 2. Connect White Wire from Wire Harness (L) to Orange Wire. Scotch Lock, ullet Connector, or solder. See Fig.. 10
11 Wiring Details, continued attery Connections (Right) lack - To Negative (-) Route Wire Harness (L) along Frame and secure with Wire Ties (not included) Red - To Positive (+) 11
Item Description Qty. C Mounting Bracket Support 1 D* ECU Mount 1
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