Holeshot Performance Products, Inc.

Holeshot Kawasaki ZZR-1200 Slip-ons
Installation and Carburetor tuning tips

This tip page is to be used in conjunction with the instruction sheet included with your slip-ons.

Slip-On Installation Tips

(Click the image thumbnails for a larger view)

	Be sure the 4" stainless muffler clamp offset is installed as pictured. This will give the mufflers the proper swing arm clearance.
	The 4" stainless muffler clamp should have 1/8" to 1/4" clearance from the front edge of the clamp to the muffler rivets. The clamp should be mounted straight on the muffler front to back.
	This photo illustrates the approximate location of the center stand stop.
	Be sure the brake pedal linkage clears the right elbow pipe and adjust if necessary per my instruction sheet.
	To fine tune the muffler height and alignment, put the bike up on the center stand on level ground and measure from the floor up to the top center of each exhaust tip. Adjust accordingly until they are even with the tips pointing straight down.
	This is the look you are going for when finished from the rear view.

Carburetor tuning tips

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	Tip: Always have a factory service manual handy for reference.
	Remove the seat, side panels and fuel tank.
	Remove the air box lid, air filter, then the complete air box from the carburetors.
	Loosen the intake manifold clamps and remove the carbs from the manifolds. This can be done by unplugging the four wire connectors, removing the one lower fuel line and disconnecting the choke cable.
	Lay rags over the intake ports and a towel on the engine. Turn the carbs on end as shown and use a bungee cord to help hold them in this position. Removing the float bowls is not necessary. Dale was experimenting with jetting when this photo was taken.
	This is the pilot fuel adjustment screw that is covered by a pressed in plug. This located in the tower shaped casting sticking down out of the carburetor. To remove it, carefully drill out the plug with a new 1/8" drill bit. Be sure not to drill any further than the plug, which could damage the adjustment screws. Once drilled screw a 1" long #8 pan head sheet metal screw into the plug, grab the screw head with vise grips and carefully twist out the plug. Blow out any chips, being careful not to let them get into the carbs. With the plugs removed turn the fuel screws gently clockwise until they bottom, then back out 2 full turns. This is my base setting and the adjustment window is 2 to 3 turns. In is leaner and out is richer. This will mostly effect the idle, off idle and mid range performance. Note: Do not remove the float bowls! Dale was experimenting with jetting when this photo was taken.
	Remove all four carb tops one at a time. Remove the needle assembly from the slide and add two Holeshot mill spec stainless shims to the needle as shown per my base setting. Only one shim is shown in this example photo. One shim will be slightly leaner while two or three is a richer mixture setting. This will effect the mid range roll-on, steady cruise and top end power. Note: Changing jets is not needed to achieve good performance gains and overall smooth running with our slip-ons installed.
	Carefully reinstall the slide diaphragms making sure they are properly seated in the retaining groove of the carburetor body. Note: Be sure the brass insert is properly located and seated in the carb body. Install the diaphragm springs and all four carb tops. Carefully reassemble the bike in the reverse order of disassembly. Fire up the motor and let it warm up fully, then set the idle at 1000 to 1200 rpm. Now go test ride and enjoy your new smoother running and much faster ZZR-1200 with your new Holeshot slip-ons and simple carb tweak. Please let us know how you like your Holeshot ZZR slip-ons and simple carb tweak by dropping Dale a note here.

Disclaimer
All Holeshot Performance Products are intended for closed course racing purposes only, never to be used on any road or highway anywhere in the world. Many of our products are illegal on pollution controlled vehicles so installing them is at the sole discretion of the buyer. Be sure to check your local laws. Holeshot Performance Products is not responsible for any engine damage that may occur from improper installation of any of its products. Holeshot Performance Products, Inc. ® is a trademark of Holeshot Performance. Any other product names are the trademarks of their respective holders. All rights to use this publication are exclusively owned by, and proprietary to, Holeshot Performance Products, Inc. No part of this publication or web site may be reproduced or transmitted in any form or by any means, electronic or mechanical, without first obtaining written permission from the publisher.