Summary of Contents for Kleinn Air Horns CANX3-KIT
- Page 1 CANX3-KIT INSTALLATION MANUAL INCLUDES CALIFORNIA CARB VEHICLES REV: A (9/4/2020) © Kleinn Air Horns 2020, All rights reserved. PO Box 91278 Tucson, AZ 85752 Phone: (520) 579-1531 Web: www.Kleinn.com...
- Page 2 CANX3-KIT Installation and Operation Manual This digital PDF is interactive. Please save ink and paper… Open interactive manual using Adobe Reader ® PC, MAC, and all smart devices Go to Table of Contents PG 2/44 REV: A (9/4/2020)
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Page 3: Table Of Contents
CANX3-KIT Installation and Operation Manual Table of Contents LIST OF FIGURES ..............................5 How to Use this Manual .............................6 2.1. Interactive Manual using Adobe Reader ....................6 2.2. Your Kit SKU Number and this Manual .......................6 2.3. Illustration/Photo Details and Orientation ....................6 Safety First ................................7... - Page 4 CANX3-KIT Installation and Operation Manual 8.7. Bench Assemble Compressor with Bolts and X3-102 ................26 8.8. Bench Assemble Compressor Bracket and Rubber Bushings ..............28 8.9. Air Compressor Bracket - Installation ...................... 29 8.10. Air Compressor - Installation ........................32 8.11.
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Page 5: List Of Figures
CANX3-KIT Installation and Operation Manual 1. LIST OF FIGURES Figure 1 – Top View Showing Kit Layout (2018 X3 2 Door Shown) ................. 10 Figure 2 – Passenger Rear Fender Removal (fasteners on top of fender) .............. 19 Figure 3 – Passenger Rear Fender Removal (fasteners behind door and fender) ..........19 Figure 4 –... -
Page 6: How To Use This Manual
Your Kit SKU Number and this Manual This manual covers installation, testing, and operation of following SKU part numbers 2.2.1. CANX3-KIT (i.e., 102b Train Horn with On-Board Air System) 2.2.2. CANX3-OBA (i.e., On-Board Air System) NOTE: Illustrations and pictures contained herein may represent only one kit part number. Where critical differences exist between kits (i.e., different parts, orientation, mounting points, etc.), additional... -
Page 7: Safety First
CANX3-KIT Installation and Operation Manual 3. Safety First Read manual thoroughly before starting installation of this kit. Verify you have all parts listed and that you clearly understand this installation procedure. Contact Kleinn technical support for any questions. Installation of this kit requires moderate mechanical aptitude; seek professional help if you’re not competent using hand tools in tight uncomfortable spaces, and around possibly rusted and sharp vehicle parts. -
Page 8: Application Chart
4.1. 100% Direct Bolt-On Vehicle List CANX3-KIT is a 100% direct bolt-on aftermarket product for Can-Am vehicles listed in below chart; every effort has been made to verify correct fitment on these vehicles in their factory, non-modified conditions. MODEL YR... -
Page 9: Installation Overview
Installation and Operation Manual 5. Installation Overview 5.1. QUICK INSTALL OUTLINE For person(s) with experience installing Kleinn bolt-on kits, CANX3-KIT can be quickly installed following below: 1. Layout and organize all parts on bench 2. Select location for Quick Connect Air Coupler 3. -
Page 10: Kit Layout And Locations
Figure 1 – Top View Showing Kit Layout (2018 X3 2 Door Shown) 5.3. Approximate Installation Time CANX3-KIT is a multi-faceted product consisting of multiple mechanical, electrical, and pneumatic components. For a typical home mechanic, auto enthusiast, or technician installing a Kleinn Bolt-On kit for first time, a... -
Page 11: List Of Tools And Supplies
CANX3-KIT Installation and Operation Manual 6. List of Tools and Supplies 6.1. Standard Tool List (Required) 6.1.1. Basic mechanic’s 3/8” drive socket sets with extensions • Inch Size Sockets (1/4” – 1” Hex) • Metric Size Sockets (6mm – 20mm Hex) 6.1.2. -
Page 12: Parts List
CANX3-KIT Installation and Operation Manual 7. Parts List 7.1. Before Starting, Review Parts List Unpackage and organize Kit across a large work area and verify all parts are included, as listed below. Contact Kleinn support if any questions arise. 7.1.1. Review pre-packaged Kit items (i.e., K1, K2, etc.) 7.1.2. -
Page 13: Air Fittings And Related Items
CANX3-KIT Installation and Operation Manual 7.3. Air Fittings and Related Items ITEM PART NUMBER DESCRIPTION PICTURE 2151 1/4" NPT PRESSURE SWITCH (view location on Air Tank) 54440 1/4" NPT "T" MANIFOLD, FEMALE (view location on Air Tank) 51414NPTL 1/4" NPT X 1/4" NPT FEMALE, 90 (view location on Air DEG. -
Page 14: Electrical Small Components And Related Items
CANX3-KIT Installation and Operation Manual 51414F 1/4" NPT X 1/4" TUBING FEMALE, STRAIGHT (USED ON COMPRESSOR LEADER HOSE END) 25014 1/4" AIR TUBING, 20 FT. LONG (USE 6 FT. FOR COMPRESSOR, 14 FT. FOR AIR HORN) KLEINN AIR HORN THREAD SEALENT FOR NPT... -
Page 15: Bolt-On Mounting Brackets & Special Hardware
CANX3-KIT Installation and Operation Manual 1" OD X 1FT. LONG 1” WIRE LOOM CORRUGATED AND SPLIT 321-W HORN ROCKER SWITCH, WITH BACKLIT HORN LOGO 7.5. Bolt-On Mounting Brackets & Special Hardware ITEM PART NUMBER DESCRIPTION PICTURE X3-101 COMPRESSOR BRACKET, WELDMENT... -
Page 16: Hardware, Fasteners And Soft Parts
CANX3-KIT Installation and Operation Manual X3-204 SPACER, BRACKET HALF, MACHINED X3-301 HORN BRACKET, CUT AND FORMED X3-302 HORN STABILIZER BRACKET, CUT AND FORMED 7.6. Hardware, Fasteners and Soft Parts NOTE: Pictures only indicative, not to scale and may not represent exact item ITEM QTY. - Page 17 CANX3-KIT Installation and Operation Manual 5/16"-18 X 1.00" SQUARE NECK BOLT, GRADE 2, LONG ZINC-PLATED 5/16"-18 X 2.50" SQUARE NECK BOLT, GRADE 2, LONG ZINC-PLATED 5/16" ID X 0.88" OD FLAT WASHER, USS, ZINC- PLATED 5/16" ID X 0.69" OD...
- Page 18 CANX3-KIT Installation and Operation Manual M5 X 0.8 X 10MM BUTTON HEAD CAP SCREW, LONG BLACK-OXIDE 1/4" ID X 0.63" OD FLAT WASHER, SAE, BLACK- OXIDE LOCK WASHER, SPLIT, BLACK- OXIDE 1 1/16" OD X 1/2" ID PRESS-IN RUBBER GROMMET X 3/8"...
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Page 19: On-Vehicle Mechanical Assembly Steps
CANX3-KIT Installation and Operation Manual 8. On-Vehicle Mechanical Assembly Steps 8.1. Plan Location of Quick Connect Air Coupler 8.1.1. Before installing Brackets, review how kit installs and decide whether to install coupler to vehicle body, frame, or onto supplied brackets; this facilitates later routing Air Tubing and attaching Coupler. - Page 20 CANX3-KIT Installation and Operation Manual 8.2.4. Remove single T15 screw holding rear of fender near inside of brake light, as shown below. FRONT T15 Screw Figure 4 – Passenger Rear Fender Removal (below tail light) 8.2.5. Pull fender outwards from body and rest on tire to reduce stress on Brake Light Wiring, as shown below.
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Page 21: Remove Driver Side Rear Fender
CANX3-KIT Installation and Operation Manual 8.3. Remove Driver side Rear Fender 8.3.1. Repeat previous steps for Passenger Fender removal. 8.4. Air Tank Brackets - Installation 8.4.1. Gather Brackets X3-201, X3-202, X3-203 and X3-204 (2) 8.4.2. On passenger side of vehicle, remove two (2) bolts holding Rack; as shown below. Do not discard large bolt, as it will be re-used. - Page 22 CANX3-KIT Installation and Operation Manual 8.4.3. Install Air Tank Bracket (X3-202, 203 & 204) on chassis tube, using hardware #H5, H6, H8, H9 & H10, as shown below. Hand-tighten hardware only, so Bracket can still be rotated and moved along tube.
- Page 23 CANX3-KIT Installation and Operation Manual 8.4.4. Install Air Tank Bracket X3-201 onto Rack support tubes, using hardware #H11, H12, H13, H15 & H16, as shown below. Hand-tighten hardware only, so Bracket can still be adjusted for Air Tank, as needed.
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Page 24: Air Tank Fittings - Bench Assembly
CANX3-KIT Installation and Operation Manual 8.5. Air Tank Fittings - Bench Assembly 8.5.1. Gather all necessary Air Fittings and Air Tank; ensure all threads on fittings and inside ports are clean. 8.5.2. Apply two small drops of Kleinn Air Horn Juice to each male pipe thread. -
Page 25: Air Tank - Installation
CANX3-KIT Installation and Operation Manual 8.6. Air Tank - Installation 8.6.1. Before starting, ensure at least 6 FT. of supplied ¼” Air Tubing is connected to Air Tank front port, to allow easily routing across rear firewall/chassis and connecting to Air Compressor. -
Page 26: Bench Assemble Compressor With Bolts And X3-102
CANX3-KIT Installation and Operation Manual 8.7. Bench Assemble Compressor with Bolts and X3-102 8.7.1. Remove Compressor from packaging. 8.7.2. Remove Brass Sleeves and Rubber Bushings from chrome feet; set aside. Use care not to tear Bushings. 8.7.3. Using hex wrench, remove chrome feet from Compressor and discard, as shown below. - Page 27 CANX3-KIT Installation and Operation Manual 8.7.5. Attach Leader Hose Support Bracket (X3-102) on back of Compressor using supplied Hardware H14, as shown in above and below figures; also reference Figure 25 below. 8.7.6. Open included* hardware bag (inside Compressor package) and install bolts, lock washers, and flat washers to Compressor, as shown below;...
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Page 28: Bench Assemble Compressor Bracket And Rubber Bushings
CANX3-KIT Installation and Operation Manual 8.8. Bench Assemble Compressor Bracket and Rubber Bushings 8.8.1. Insert Rubber Bushings and Brass sleeves into Compressor Bracket, as shown below in Figure 17 and Figure 20 INSERT BRASS SLEEVE INTO THIN SIDE OF BUSHING (I.E.., FRONT SIDE) RUBBER BUSHINGS &... -
Page 29: Air Compressor Bracket - Installation
CANX3-KIT Installation and Operation Manual 8.9. Air Compressor Bracket - Installation 8.9.1. Gather X3-101 bench assembled Bracket, from prior step. 8.9.2. On Driver side of vehicle, remove front bolt holding Rack; as shown below. M6 bolt and nut (i.e., front bolt) will be replaced and may be discarded. - Page 30 CANX3-KIT Installation and Operation Manual 8.9.4. Using hardware #H11, H12, H13, H15 & H16, attach Air Compressor Bracket below Rack Support Tubes in same fashion, as performed during Air Tank installation (Figure 10). Leave fasteners slightly loose, to enable Bracket to be re-positioned, as needed.
- Page 31 CANX3-KIT Installation and Operation Manual 8.9.6. With Air Compressor in place, adjust Bracket side-to-side, as required to maintain at least 1/8” clearance between Air Compressor Head and Rack, as shown below. Once position is obtained, final torque Rear Bolt of Rack to 49 lbf-in.
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Page 32: Air Compressor - Installation
CANX3-KIT Installation and Operation Manual 8.10. Air Compressor - Installation 8.10.1. Route 1/4” Air Tubing, which is connected to front of Air Tank from bench assembly step (Figure across back of firewall, or above chassis, as desired. There should be at least 12 inches of excess tubing sticking out of Driver’s side to manipulate and connect to Air Compressor. - Page 33 CANX3-KIT Installation and Operation Manual 8.10.2. Install Air Compressor on Bracket using hardware included* inside Compressor packaging and place Fender Washer (H19) on both sides of Rubber Feet, as shown below. Final torque all bolts. Connect previously routed 1/4” Air Tubing to Leader Hose end, and secure all Air Tubing using supplied zip ties.
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Page 34: Air Horn - Installation
CANX3-KIT Installation and Operation Manual 8.11. Air Horn - Installation 8.11.1. Disassemble Trumpets from Air Horn Driver (item 3 in below picture), by grasping Trumpet throats with hand and twisting counter-clockwise; it may be necessary to clamp Air Horn Driver. Air Horn should be separated into three components, as shown below. - Page 35 CANX3-KIT Installation and Operation Manual 8.11.4. Remove three (3) M12 OE bolts that hold front sway bar and remove small T30 bolt holding Brake Line next to firewall, as shown below. Use care removing fasteners, as they will be re-used.
- Page 36 CANX3-KIT Installation and Operation Manual 8.11.7. Install X3-302 Trumpet Support Clamp and Insert Trumpets, using hardware H8, H9 & H10. Loosely tighten hardware, so X3-302 can still be positioned. Once hardware is installed, remove tape holding bottom side of carriage bolts to Bracket.
- Page 37 CANX3-KIT Installation and Operation Manual 8.11.8. On bench, connect remaining amount of supplied 1/4” Air Tubing to Air Fitting on Air Horn Solenoid, then install Air Horn Driver to Bracket using hardware H1, H1, H3 & H4. Loosely tighten hardware, as shown below.
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Page 38: Connect Remote Quick Connect Kit To Vehicle
CANX3-KIT Installation and Operation Manual 8.11.10. Route Air Tubing back to Air Tank, as desired and safely secure to frame away from heat and sharp edges using zip-ties. Attach to proper port listed in figure 12 above. 8.11.11. Final installation of Air Horn should match below pictures. -
Page 39: On-Vehicle Electrical Installation
CANX3-KIT Installation and Operation Manual 9. On-Vehicle Electrical Installation CAUTION: Follow all recommended safety precautions for working on vehicle’s electrical system; consult vehicle owner’s manual for further instruction. 9.1. Relay and Fuse Diagram for Air Horn System Figure 37 – Suggested Ignition Relay Diagram for Air Horn System... -
Page 40: Review Suggested Wire Routing For Air Horn System
CANX3-KIT Installation and Operation Manual 9.2. Review suggested Wire Routing for Air Horn System Figure 38 – Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch 9.3. Disconnect Vehicle Battery(s) 9.3.1. Remove Passenger side seat or move it forward to expose Battery. Consult Owner’s Manual. -
Page 41: Install Horn Button
CANX3-KIT Installation and Operation Manual 9.4.2. Insert all wiring into included wire loom and ensure loom is away from all sharp edges, hot vehicle parts (i.e., exhaust, engine, radiator), and fasten securely to vehicle using zip ties, or equivalent. NOTE: Do not cut wires to length until 100% sure of length required for final connections. -
Page 42: Initial Testing Of Kit
CANX3-KIT Installation and Operation Manual WARNING: NEVER operate train horns with ears 10. Initial Testing of Kit close to trumpets or in an enclosed space 10.1. Reconnect Vehicle Battery(s) without substantial hearing protection (i.e., > CAUTION: Before connecting vehicle battery(s),... -
Page 43: General Operation Of Kit
CANX3-KIT Installation and Operation Manual 12.1. Yearly, or every 12000 miles verify all 11. General Operation of Kit mounting fasteners are properly torqued; 11.1. Compressor Operation applying witness marks across fasteners and mounting parts is good practice to quickly WARNING: Never operate Air Compressor above ensure fasteners have not moved. -
Page 44: Warranty Information
Installation and Operation Manual 13. Warranty Information Thank you for purchasing this CANX3-KIT. Shall you experience any unexpected problems during installation or have problems with any part at any time please contact Kleinn support. © Kleinn Air Horns 2020, All rights reserved.
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