NOS AC 400 Z400 Installation Instructions

780 Professional Dr. North, Shreveport, La 71105
Phone: 318-524-2270 Fax: 318-524-2297
SUZUKI Z400, KAWASAKI 400, AND
ARCTIC CAT 400
CUSTOM INSTALL NOTES:
For how to instructions: See the Holly Performance instructions supplied with this
kit. This set of notes is to help your installation by giving application specific
examples. These examples have been tested and found to work. These are only
suggestions if there are any installation modifications that you feel will make your
bike unique feel free to make those modifications. Remember to read the main set
of install instructions so that you have a good understanding of how nitrous can
work for you.
Note: There are only minor differences between the Suzuki, Kawasaki, and Arctic
Cat 400’s
NOTICE: Installation of Nitrous Oxide Systems Inc. products signifies that you
have read this document and have agreed to the terms stated within.
It is the purchaser's responsibility to follow all installation instruction guidelines and safety
procedures supplied with the product as it is received by the purchaser to determine the
compatibility of the product with the vehicle or the device the purchaser intends to install the
product on.
Nitrous Oxide Systems Inc. assumes no responsibility for damages occurring from accident,
misuse, abuse, improper installation, improper operation, lack of reasonable care, or all
previously stated reasons resulting from incompatibility with other manufacturers' products.
Nitrous Oxide Systems Inc. assumes no responsibility or liability for damages incurred by the use
of products manufactured or sold by Nitrous Oxide Systems Inc. on vehicles used for competition
or racing.
Nitrous Oxide Systems Inc. neither recommends nor condones the use of products manufactured or sold by
Nitrous Oxide Systems Inc. on vehicles, which may be driven on public roads or highways, and assumes no
responsibility for damages incurred by such use.
NOS nitrous oxide is legal for use in most states when used in accordance with state and local traffic laws. NOS
does not recommend or condone the use of its products in illegal racing activities.
NOS has not pursued California Air Research Board (GARB) exemptions for its kits, hence, they are not legal for
use on pollution-controlled vehicles in California. A correctly installed NOS nitrous system should not alter the
emission control performance of your vehicle under standard ERA test cycle conditions.
HAZARDS DEFINED
This manual presents step-by-step instructions that describe the process of installing your NOS Nitrous Oxide Injection
System. These procedures provide a framework for installation and operation of this kit. Parts are referenced by name
and number to avoid confusion. Within the instructions, you are advised of potential hazards, pitfalls, and problems to
avoid. The following examples explain the various hazard levels:
WARNING! Failure to comply with instructions may result in injury or death.
CAUTION! Failure to comply with instructions may result in damage to equipment.
NOTE: This information is important, needs to be emphasized, and is set apart from the rest of the text.
HINT: These special instructions provide a handy work tip.
NITROUS OXIDE INJECTION SYSTEM
SAFETY TIPS WARNINGS
Do not attempt to start the engine if the nitrous has been injected while the engine was not running. Disconnect the coil wire
and turn the engine over with the throttle wide open for several revolutions before attempting to start. Failure to do so can
result in extreme engine damage.
Never permit oil, grease, or any other readily combustible substances to come in contact with cylinders, valves, solenoids, hoses,
and fittings. Oil and certain gases (such as oxygen and nitrous oxide) may combine to produce a highly flammable condition.
Never interchange nitrous and fuel solenoids. Failure to follow these simple instructions can result in extreme engine damage
and/or personal injury.
Never drop or violently strike the bottle. Doing so may result in an explosive bottle failure.
Never change pressure settings of the safety relief valve on the nitrous bottle valve. Increasing the safety relief valve pressure
settings may create an explosive bottle hazard.
Identify the gas content by the NOS label on the bottle before using. If the bottle is not identified to show the gas contained,
return the bottle to the supplier.
Do not deface or remove any markings, which are on the nitrous bottle.
Nitrous bottle valves should always be closed when the system is not being used.
Notify the supplier of any condition, which might have permitted any foreign matter to enter the valve or bottle.
Keep the valves closed on all empty bottles to prevent accidental contamination.
After storage, open the nitrous bottle valve for an instant to clear the opening of any possible dust or dirt.
It is important that all threads on the valves and solenoids are properly mated. Never force connections that do not fitproperly.
BOTTLE MOUNTING:
We have found that the bottle mounts very nicely on the left hand side of the ATV above
the left rear tire. The bottle mounts to the front hole on the frame bracket see below
illustration. Remove the “U” shaped piece from the bottle mounting bracket, insert the
threaded stud into the front hole, apply washers and Teflon nut and tighten into place.
Note: hole to the left works
the best for mounting the
bottle
Note: bottle position after
mounting.
SOLENOID MOUNTING:
We have found that the nitrous and fuel solenoids will mount very nicely beneath the seat
catch in the shape of a “V” see below illustration. The nitrous solenoid mounts to the
right and the fuel to the left. The hole that is used for mounting the solenoid brackets is
an existing hole. Use the bolt that is supplied in the custom kit to mount the bracket to
the frame. You will have to notch the catch on the seat slightly to compensate for the
bolt sticking up.
Note: brackets are mounted in the
shape of a “v” with the nitrous
solenoid to the right.
Note: a notch is cut in the seat
catch to compensate for the bolt.
FOGGER NOZZLE INSTALLATION:
The rubber boot that mounts the carburetor to the intake is the best place to mount the
fogger nozzle. Loosen the clamp that secures the rubber boot to the carburetor and the
intake and remove the boot completely. The 7/16” hole will be drilled in the widest part
of the rubber boot.
Note: The widest part on the
rubber boot is where the 7/16”
hole will be drilled.
Note: The fogger nozzle mounted into
the rubber boot
ELECTRICAL COMPONENTS MOUNTING:
The 30 amp relay module mounts well above the battery along the right hand side of the
plastics and behind the battery stabilizer. The activation switch mounts on the right hand
side on the front fender where the plastics dip down between the body plastic and the tire
cover plastics. This is a low spot and is well protected.
Replace the throttle stop screw with the full throttle activation button.
Note: drill a small hole in the plastic
and mount the relay module to the
plastic
Note: position of activation switch.
Install switch so that when lever is up
the nitrous system is activated.
Note: The full throttle activation switch replaces the throttle stop screw on the cable
retractor box, which is on the right handle bar.
JETTING FOR THE 400EX: On most stock 400s a 22 jet on the nitrous and a 26 jet on
the fuel is the setting you will be happy with. Depending on the mods that you have done
the jetting will vary. No matter what mods you have done, 22 and 26 is a good place to
start. Our recommendation is to start small and work up from there. See four stroke
instructions for system testing instructions.
System testing:
1. Check to see if the fuel pump and solenoids are functioning:
A. Turn on the activation switch and listen for the fuel pump to turn on. You should
hear a humming. If you do not hear the humming then check all wiring and
connections.
B. In order to check the solenoids, turn on the activation switch and push the throttle
all the way to activate the full throttle activation switch. When you do this listen
for the solenoids to “click”. If you do not hear the click, then check all the wiring
and connections.
2. Once the fuel pumps and solenoids are working, you need road test the system. The first
couple of runs will be made without nitrous. The activation switch should be on and the
nitrous bottle should be off (there should be no nitrous pressure in the braided line. If
there is, bleed out the line by loosening the braded line from the bottle.). Run the bike just
like you would with nitrous. What is being done on this step is priming the fuel line with
fuel. It is a good idea to get into the habit of doing this step if you go for extended periods
of time without running the nitrous. What you will feel when the nitrous button is pushed
is a bogging down of the engine; this is caused by an excess of fuel into the head. After
you have primed your fuel system, turn on the nitrous bottle. Make a pass with the nitrous
system on and at full throttle one of four things will happen at this point:
A. It will work great and you will be very happy.
B. It will fall on its face (this is an indication of too much fuel being injected). If it
falls on its face then there is too much fuel being injected with the nitrous. Close
the gap between the nitrous and fuel. Example: if your nitrous jet is a 20 and your
fuel jet is a 24; replace the fuel jet with a 22 and test the system again.
C. I will start to detonate (this is an indication of a lean condition). If it starts to
detonate not enough fuel is being injected with the nitrous and you will need to
widen the gap between the nitrous and fuel. Example: if you nitrous jet is at a 20
and your fuel jet is at a 22 widen the gap between the two by dropping the nitrous
jet down to an 18. Always go down with the nitrous first and then work back up
with the nitrous and fuel together once you have eliminated the detonation
problem.
D. You do not feel much of a difference when you hit the nitrous button (this
indicates not enough nitrous and fuel for the size of engine that you have). If you
do not feel much of a difference increase the size of the nitrous and fuel jets one
step at a time until you have reached your desired horsepower increase.
There are only two things that will destroy your motor, running too lean for too long and
exceeding the capacity of what your motor can actually handle. Understand the limits of what
your ATV and stay within them!!