Ram Air Brace install guide
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Kawasaki ZX-10R

Ram Air Support Brace

 

 

This product is designed to help support the Ram air tube on the 2004-2005 zx10r which is prone to breaking due to wheel stands, crashes and other stresses. It can be used with an unbroken ram air tube or with a repaired ram air tube.

 

The brace has been CNC cut from lightweight 2mm aluminum for maximum strength combined with minimum weight. The Ram Air Support Brace should be supplied with the necessary replacement and extra bolts, two larger types and four smaller types with washers and nuts.

 

Bolting the support brace to the ram air tube requires 4 holes to be made in the tube however doing so is optional (but recommended for maximum strength).

 

The following are some basic instructions to help you install your ZX-10R Ram Air Support Brace. It is recommended that you read these before attempting installation. If you are unfamiliar with your motorcycle it may be necessary to consult a workshop manual. The whole install should take around 1 to 2 hours depending on your ability and experience.

 

If you do not feel confident or are uncertain of your ability installing this product, it is recommended that you have your mechanic install them for you.

 

Make sure you have adequate room to work, suitable quality tools and all parts and supplies needed.

 

 

 

1. You will need to remove your front fairing, mirrors, headlight and instrument cluster. It may be necessary to consult your workshop manual.

2. Remove the Ram Air tube from the front of the bike, repair if necessary. Broken tabs can be super-glued or epoxy’d back on. Ensure tabs are straight when gluing.

 

3. Mount the Ram Air Support Brace on the ram air tube as shown below. Bolt it to the tabs using two of the original bolts and the two longer bolts supplied.

4. Make sure the Ram Air Support Brace sits snugly around the Ram Air tube. Mark the center of the four holes on the two sides of the Ram Air tube with a nail, pin or a good marker. The two holes on the left side are circled in red in the photo above.

 

5. Remove the Ram Air Support Brace and drill four 4mm holes where marked previously.

 

6. Re-install the Ram Air Support Brace and bolt it to the Ram Air tube using the four nuts and bolts provided.

 

7. Re-install the Ram Air tube along with the Ram Air Support Brace onto the bike. Use two original bolts on the upper two mounting holes and the two longer bolts supplied on the lower mounting holes. Don’t forget to mount the cable guides as well.