Installation Instructions
Contents
1. 10 STEP 11 STEP 12 STEP 13 STEP 14 STEP 15 STEP 16 STEP 17 STEP 18 ATTENTION ATTENTION Ride On Kuryakyn Loosen the clamps securing the stock rubber elbows to the carburetors and air box Gently wiggle the air box to ensure that the rubber intake duct is fully seated on the air box inlet wry PIC 5 removing the air box lid makes it much easier to see if it is on completely Once everything is situated and comfortably in place tighten the clamp on the rubber intake duct first and then tighten the clamps on the stock rubber elbows Replace i the air box lid Remove the front cover of the Pro R Hypercharger Wet the radius portion of the intake duct with soapy water solution and slide the back plate of the Hypercharger into place on the intake assembly It should be between the two rubber flanges on the intake duct Install the 5 16 Barb x 1 8 NPT Right Angle Fitting in the back of the Hypercharger Using the 1 4 20 x 5 8 socket heads and flanged nuts bolt the Hypercharger back half into place See PIC 6 It is helpful to fold a portion of the radius back while performing this procedure Install the K amp N filter and the Filter Cage Assembly Replace the front cover of the Pro R Hypercharger fastening with the supplied fasteners in the bag in the Hyper Install the 2 small screws into the Pro R end caps without using the washers Tighten all Screws See2. PIC 7 This is the vacuum nipple in the front carb Connect the supplied vacuum hose to this nipple and connect the remaining end to the vacuum nipple on the bottom of the Hypercharger IMPORTANT See PIC 8 PIC 9 and PIC 10 This is the float bowl vent hose Connect this hose to the black right angle fitting on the back of the Hypercharger Replace the fuel tank and re connect the positive battery cable re install seats Double check the tightness of all related fasteners check for hose n clearance and check throttle for correct operation making sure it returns properl p r g properly pic 8 e 4 j before starting the bike It is the installer s responsibility to ensure that all of the fasteners including M vent Hose preassembled are tightened before operation of the motorcycle Kuryakyn will not z warranty components lost due to improper installation Periodic maintenance may be required Some of our high performance air cleaners extend beyond the stock OEM unit to achieve smoother air flow and better performance Riding position may be affected ATTACH TO ELBOW ON THE BACK OF HYPERCHARGER PRO R HYPERCHARGER INSTALLATION
3. battery and tuck it out of the way to reduce the possibility of sparks STEP 3 Remove the two rear tank mounting bolts Remove the plastic tank mounting snap stud Push in on the center of it to release Slide the tank back to expose the top of the engine Make sure the tank is secured so it does not fall You may remove the tank completely if so desired STEP 4 Remove the stock air cleaner cover element and backing plate The top and rear mounts are secured with screws the front mount snaps into a grommet STEP 5 See PIC 1 and PIC 2 Remove the grommet from the bracket STEP 6 Placing your long handled Phillips screwdriver as shown in PIC 3 loosen the clamp on the air duct and remove the duct Remove the clamp from the duct and set it aside as it will be reused N NOTE Now is a good time to proceed with re jetting of the carburetors Consult i your factory service manual for this procedure We have supplied jets to cover most common applications PAGE 2 PRO R HYPERCHARGER INSTALLATION cont Kuryakyn Jetting Recommendations See FIG 1 for jet locations With stock exhaust or Cobra Slip On Mufflers e 1 2 Pilot Air Bleeds in both carbs e One 020 shim added to raise each needle 122 5 Main Jet in the front cylinder s carb 120 Main Jet in the rear cylinder s carb Pilot Mixture Screw PMS 2 turns out from lightly bottomed vw With Vance amp Hines Samson or
4. INSTALLATION PRO R HYPERCHARGER for YAMAHA 9463 PARTS INCLUDED 1 Pro R Hypercharger Assembly Including The Following Items 5 Screws in Plastic Bag Including 3 1 4 20 X 1 5 8 Button Socket Cap Screws 2 6 32 X 3 8 Socket Head Cap Screws 2 6 Flat Washers NOT USED 1 Dual Velocity Ring NOT USED 1 Filter Cage Assembly 3 PC 1 Hyper Filter Round 1 1100 V Star Bracket Manifold Hardware Kit 1 Ribbed Rubber Hyper Duct 1 Internal Duct Support Black Plastic 1 Steel Chrome Bracket 1 Hardware Kit Including The Following 3 M6 Aluminum Tapered bolt Cap 3 M6 x 1 0 x 16mm Socket Head Cap Screw 1 M6 Flange Nut 1 Step Reducer Washer 3 1 4 20 x 5 8 Socket Head Cap Screw 3 1 4 20 Flange Nuts 1 12 Length of Vacuum Hose 8 M4 x 10mm Socket Head Cap Screw 1 90 Degree Elbow 2 020 Thick Needle Shim 1 Galvanized Clamp Hook 1 Jet Kit Includes the Following Four Items 1 125 Main jet 2 1 2 Pilot Air Bleed 1 120 Main Jet 1 122 5 Main Jet 1 Installation Instructions Please read and understand entire instructions before starting installation THANK YOU FOR CHOOSING KURYAKYN IN ORDER TO PROTECT YOU AND OTHERS FROM POSSIBLE INJURY AND OR PROPERTY DAMAGE OR LOSS PLEASE PAY CLOSE ATTENTION TO ALL INSTRUCTIONS WARNINGS CAUTIONS AND ATTENTION NOTES REGARDING THE USE AND CARE OF THIS PRODUCT WARNING THIS INDICATION ALERTS YOU TO THE FACT THAT IGNORING THE CONTENTS DESCRIBED HEREIN CAN RESULT IN POTENTIAL DEATH OR SE
5. RIOUS INJURY ATTENTION This indication alerts you to the fact that ignoring the contents described herein may negatively affect product performance and functionality CAUTION This indication alerts you to the fact that ignoring the contents described herein can result in potential injury or material damage TOOLS SUGGESTED Set of Metric and Standard Hex Wrenches Set of Metric Combination Wrenches Phillips Screwdriver 9463 24MC 1011 cont CUSTOMER SERVICE INSTALLATION QUESTIONS LIMITED WARRANTY ereunder sh STRICTLY OBSERVE THE FOLLOWING GUIDELINES IN ORDER TO USE THE PRODUCT Kuryakyn PROPERLY AND AVOID POTENTIALLY DANGEROUS ACCIDENTS STEP 1 Read and understand all steps in the instructions before starting the installation Park the motorcycle on a hard level surface and turn off the ignition Let cool DISCLAIMER PLEASE READ BEFORE PROCEEDING Any modifications to a motorcycle s exhaust or intake tract require carburetor re jetting to achieve maximum performance and maintain drivability If you are uncomfortable with the process of tuning your carburetor we recommend that you bring your motorcycle to a qualified motorcycle mechanic to have this kit installed The jets included in this kit were selected based on test results with various combinations of components that we felt would represent the majority of the customers purchasing this kit see Addendum I However no two motorcycles are exactly alike Dependi
6. ng on the individual case additional jets may need to be purchased from an outside source Kuryakyn warrants the parts included in this kit to be free of defects in materials and workmanship but makes no claim whatsoever in regard to costs associated with installation or tuning WARNING YOU WILL BE WORKING AROUND THE ENGINE AND EXHAUST SYSTEM DURING INSTALLATION ENSURE THAT THE ENGINE AND EXHAUST SYSTEM HAVE FULLY COOLED TO PREVENT INJURY ATTENTION A factory service manual may be helpful in performing this installation Do not attempt to perform this installation if you are not confident in your ability to complete all of the steps in the procedure consult a trained technician CAUTION The installation of any high performance exhaust system can cause a lean fuel air mixture A lean fuel air mixture can cause engine overheating resulting in severe engine damage 3 Kuryakyn recommends rejetting carbureted bikes z ee 4 t fl 4 a r a fd ee REMOVE THIS GROMMET Fi NOTE This installation requires re jetting of the carburetors This is an involved procedure that we recommend be performed by a qualified service technician If you choose to attempt this procedure yourself refer to the carburetor removal disassembly reassembly and installation procedures outlined in your V Star service manual STEP 2 Remove the driver and passenger seats from the bike Remove the negative battery cable from the
7. open Drag pipes e 1 2 Pilot Air Bleeds in both carbs One 020 shim added to raise each needle 125 Main Jet in the front cylinder s carb 122 5 Main Jet in the rear cylinder s carb Pilot Mixture Screw PMS 2 turns out from lightly bottomed NOTES A The factory installed plug covering the PMS will have to be removed in order to access the screw B Because the float bowl screws are easily damage during removal we have included 8 replacement float bowl screws with socket heads just in case they are needed BE SURE TO VENT THE FLOAT BOWLS TO THE BACK OF THE HYPERCHARGER THIS IS NECESSARY FOR BEST DRIVABILITY AND MAXIMUM PERFORMANCE See STEP 16 STEP 7 See PIC 4 Insert both flanges of the rubber air duct through the opening in the mounting bracket Place the galvanized clamp hook on the duct clamp as shown in PIC 4A You will need to flatten this hook on the clamp Place the Stock duct clamp on the new intake duct the clamp screw should face forward See PIC 4B STEP 8 Install the mounting bracket and duct assembly using the supplied M6 x 1 25 x 15mm socket heads and tapered socket head bolt caps The front mounting point will also use the step reducer washer and M6 flange nut Make sure the intake duct is in position on the air box inlet Tighten the bracket securely but leave the clamp on the intake duct loose for now See PIC 5 SCREW FACES FORWARD F JG PRO R HYPERCHARGER INSTALLATION STEP 9 STEP
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