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INSTALLATION MANUAL

1. 9 E Fuel Controller Fitment secte ertt T 10 F Signal Line Routing Pictorial 11 i Harley Davidson FL Series Turbo System Installation Manual WARNINGS AND DISCLAIMERS Any aftermarket power adding product can be dangerous to a vehicle if not used as directed Aerocharger Turbo Systems are properly engineered manufactured with high quality components and heavily tested to ensure best possible reliability However many factors that are out of our control such as installation errors or misuse can potentially cause damage When properly installed and configured this system should outlast the life of the vehicle Please note the following warnings carefully follow all instructions and do not hesitate to contact an Aerocharger tech if you are unclear about any guidelines listed here INSTALLATION WARNING If you are uncomfortable performing any installation procedure as described in this manual please consult a trained professional at a qualified performance shop If you are performing the installation of this system yourself we recommend reading the entire manual before beginning the installation We also suggest that you review your progress after each section to ensure that everything has been correctly installed MODIFICATION WARNING This system is designed for use on a stock 2008 Harley Davidson FL Series motorcycle with an undamaged well
2. SYSTEM INSTALLATION MANUAL 2 AEROCHARGE 7 CJ Q HARLEY DAVIDSON FL SERIES INTRODUCTION Congratulations on your purchase of an Aerocharger Turbo system for Harley Davidson FL Series motorcycles You now own the most powerful reliable and technologically advanced turbo system in the world With your new turbo system installed you will experience substantial performance gains Our unique system combines VATN technology with our frictionless non flooded ceramic ball bearing system which provides zero lag performance This system is proudly made and assembled in the USA by Aerocharger LLC CONTENTS i I Install the Headers eese eene nnnm XMAS onenen nin E EEN E 2 IH Duel C OE ONCE ossasensst quieto rope Codi OSEE To 4 WADO INSI 5 V Charge sesto etia 6 VI Intercooler and Charge 6 RG T 7 Vill nal lee 8 ADDED iren anna auqa hayantassamashhsatyspassatphastasqhunmaqiasaquukashashukuthushanpsi asa 9 ME MIN UT 9 D Epgine Upgrades 9 C Vehicle Maintenance eene eene 9 D Aerocharger Maintenance
3. Visit us online at www AEROCHARGER com for more technical resources such as Digital versions of manuals and field guides Detailed video of installations to refer to during your install Up to date tips tricks and upgrades WE WANT SEE YOUR AEROCHARGER BUILD Shoat some video or take a picture Post it online Be sure to tag Aerocharger Get featured on our website or Facebook Lb wo AEOCUAREER com HNNENSNENNNESNESNSSNESNBNESNMNSE HN HN BE B HARLEY DAVIDSON FL SERIES By Aerocharger LLC 402 New Century Parkway New Century KS 66031
4. Disconnect the injector retaining bracket with a 27mm Torx screwdriver Unplug the injector connectors and pull out the injectors with their harness Unclip the wires at the plastic connector never disconnect by pulling on the wires www AEROCHARGER com 913 829 3400 infoajaerocharger com Aerocharger Turbo Systems 8 2 Replace the stock injectors with the larger injectors 3 Reinstall the injector harness and retaining bracket included in the kit When plugging them in use gasoline Connect the injectors to the fuel controller if required or a very small amount of silicone grease to lubricate the Make sure the connection is fully seated and clicks in place injector o rings Install the injector rail at the same time to avoid pinching the o rings Use blue Loctite on the retaining bracket screw FINAL REASSEMBLY 8 With the fuel controller installed review the entire installation Verify that all wiring and lines are cleanly routed and that all connections are secure 9 2 Follow the factory service manual procedure to reinstall the gas tank seat bags side panels and all other parts that have been removed during the installation of this turbo system This completes the installation If required the motorcycle may now be taken to a qualified dyno service for tuning www AEROCHARGER com 913 829 3400 infoajaerocharger com g Harley Davidson FL Series Turbo Sys APPENDIK
5. A OCTANE The Aerocharger turbo system for Harley Davidson motorcycles has been designed to operate on 91 octane fuel available at any depending on engine mods NOTE At single hose gas pumps the first 1 5 to 2 gallons of fuel out of the line will be the grade of octane pumped by the previous cus total octane and possibly cause detonation tem Installation Manual gas station Higher octane fuel may be required tomer A mix of lower grade fuel will reduce the VEHICLE MAINTENANCE This Aerocharger system is upwardly expandable Any aftermarket power adding product can and is able to accommodate engine upgrades for accelerate wear on a vehicle However when increased horsepower output It is important properly configured operated and maintained to note that some aftermarket engine parts will the turbo system should outlast the life of the not work in harmony with this system A poor vehicle Do not neglect the normal maintenance combination of powertrain variables can reduce schedule for your vehicle and pay attention to system efficiency and cost the vehicle in overall its tune and performance and the Aerocharged horsepower Consult an Aerocharger technician motorcycle will easily be capable of thousands of for recommendations on components that work boosted miles well with Aerocharger specific applications D AEROCHARGER MAINTENANCE BOOST SPRINGS The Aerocharger is a sophisticated and highly efficient variable Aero
6. Loosely mount the Aerocharger header pipes to the engine exhaust manifold 5 Re attach the lower header mount bracket Use blue Loctite on the 5 16 18 allen bolts and torque to factory spec 3 1 LP A a NM SV www AEROCHARGER com 913 829 3400 infoajaerocharger com Aerocharger Turbo Systems 2 6 Loosely mount the turbo support bracket to the chassis at the back of the header Il TURBO AND EXHAUST 2 Set up the Aerocharger turbo Fill with the required 2 2 Install the filter on the compressor housing and amount of turbo oil 1 bottle for a 53 Series or 2 bottles for a tighten down the hose clamp to secure 66 Series Screw the fill plug back in using thread lock fluid on the threads and torque to 35 in Ibs 3 16 allen wrench Refer to Appendix D for information about setting and maintaining the Aerocharger www AEROCHARGER com 913 829 3400 infoajaerocharger com 3 Harley Davidson FL Series Turbo System Installation Manual M 2 3 Before mounting the turbo reinstall the bikes 2 4 Bolt the afterpipe flange to the turbo through the right side plastic cover Place the metal exhaust gasket on heat shield the turbo exhaust flange then loosely bolt the turbo to the header using the included hardware Use the longer bolts on the bottom to pass through the turbo support bracket 2 5 Place the retaining collar over the afterpipe t
7. charger boost springs are used to set the vane turbocharger Unlike conventional turbos it does not boost pressure Every Aerocharger is shipped require oil pumps or lines The Aerocharger will not need more with a green 5 PSI spring already installed maintenance than any other turbo this graphic contains Available springs include information for adjusting the Aerocharger to ensure best 5 PSI creen 8 PSI d es 6 PSI GREEN 9 PSI IRR f oRANGE 7 PSI ENS 11 PSI REO Bec JAn LN Wer M CONTROLLER BONNET PN 66328 BOOST FITTING PN 66335 RETAINING CLIP PN 66325 SPRING SHIMS Shims can be added to the springs to increase the boost in increments of about 5 DIAPHRAGM SHIM to 75 PSI PN 66333 CONTROLLER TOP AEROCHARGER OIL mem Specialized oil for ultra high rpm machinery Only use genuine Aerocharger Turbo Oil The wrong oil can lead to bearing failure PISTON PN 66322 005 SPRING DIL LEVELS Aerochargers consume oil throughout their use The amount of oil consumed is very small and the oil level must only be checked once a year or every 30 000 miles Aerocharger oil never has to be changed only added There is no benefit to changing the oil unless it has been contaminated with a foreign substance such as if the vehicle has been underwater for a long time CHECKING OIL LEVEL Remove the fill plug and use a zip tie as a dip stick to measu
8. harge tubes blow off valve will be closest to the airbox facing inward A reference line will connect the blow off valve to the throttle body and fuel controllers MAP sensor See Appendix F NOTE Be careful about clamp placement to avoid scratching finishes Always use blue Loctite on bolts that do not have lock washers f i j i r a i b A a E 1 P Fal j E dm P J gm y PAAA E 6 FOR INTERCOOLED SYSTEMS Bolt the intercoolers front bracket to the frame above the left passenger foot peg Then clamp the rear bracket to the bag support frame Use the inner rubber grommet to protect the finish on the frame and use thread lock fluid on all bolts NOTE Be careful about clamp placement to avoid scratching finishes Always use blue Loctite on bolts that do not have lock washers www AEROCHARGER com 913 829 3400 infoajaerocharger com 6 2 Attach the silicone charge tube with the Blow Off 6 3 Route the other silicone charge tube under the Valve to the airbox and intercooler outlet The BOV end will swingarm Attach it to the Aerocharger compressor outlet be closest to the airbox with the BOV facing inward Secure and the lower intercooler inlet Tighten the hose clamps with hose clamps A reference line will connect the blow off valve to the throttle body and fuel controllers MAP sensor See Appendix F REPLACE INJECTORS
9. hen 2 6 Attach the boost signal line to the fitting on the attach the afterpipe to the flange on the turbo Tighten Aerocharger controller bonnet and secure with a small zip down tie Without pinching the line gently secure it with a zip tie to the bag support and run the line up to the center frame See Appendix E www AEROCHARGER com 913 829 3400 infoajaerocharger com Aerocharger Turbo Systems 4 L 2 7 Place bolts through the rear mounting tab on the afterpipe Attach the afterpipe to the stock bracket on the rear bag mount and tighten securely 2 9 With the turbo headers and afterpipe installed firmly snug up all bolts and connections Tighten the engine exhaust studs first to prevent exhaust leaks FUEL CONTROLLER With the tank bags and panels removed the fuel controller can be installed at this time See Appendix E for fitment recommendations Fuel controllers are sold separately most Harley Davidson owners will want to use their preferred fuel controller with this turbo system Installation and features will vary and additional dyno tuning will be required to set the controller up on the motorcycle Contact an Aerocharger tech or a dyno tuning specialist for information and recommendations The fuel controllers oxygen sensor can be installed into this Secure the 02 sensor plug to the frame with zip ties Route bung on the afterpipe the wiring along the frame towards the fuel cont
10. maintained engine If your motorcycle is modified consult with Aerocharger before proceeding Aerocharger is not responsible for ECU tuning and programming but will provide assistance when possible ENGINE BREAK IN WARNING Installing turbo systems on brand new vehicles is not recommended New engines require a specific break in procedure that does not factor in extra stress from forced induction If the vehicle is new or has low miles consult the dealership or owners manual to determine the proper break in procedure before continuing with this installation Failure to do so can result in significant engine damage Aerocharger Turbo Systems ii WARNINGS AND DISCLAIMERS CONT D OCTANE For best performance and reliability always use the recommended octane for your specific setup See Appendix B for recommended octane Always listen for signs of detonation IF DETONATION SHOULD OCCUR OR YOU ARE UNSURE IF WHAT YOU ARE HEARING IS DETONATION DECREASE THROTTLE IMMEDIATELY and consult an Aerocharger technician If the system is installed configured and operated correctly detonation will not be an issue Please note that inconsistencies on stock engines and parts are possible on any new vehicle from an OEM INTERNATIONAL OCTANE Fuels are listed in this manual with the AKI octane rating commonly used at North American gas stations RON MON 2 Fuels that are sold in Europe and other countries generally use the RON rating system If y
11. ou are located outside of North America be sure to use the equivalent octane that is available in your region IMPORTANT NOTES NOTE Read and understand all safety and technical precautions in this manual before proceeding Failure to comply with the instructions in this manual could result in personal injury property damage voided warranties and inconsistent or poor performance from the turbocharger system Contact Aerocharger with any questions or concerns DO NOT let any debris hard or soft enter air intakes or exhaust ports during installation of this turbo kit DO NOT use any silicone sealants except as directed in this manual Silicone sealants can cause Foreign Object Damage to the turbo THIS WILL VOID YOUR WARRANTY AEROCHARGER WILL NOT BE HELD RESPONSIBLE FOR DAMAGE TO THE VEHICLE S POWERTRAIN 1 Harley Davidson FL Series Turbo System Installation Manual l INSTALL THE HEADERS Follow the factory service manual procedure to remove the motorcycles seat gas tank bags side panels and stock exhaust 2 Remove the lower header mount bracket for ease of 3 Reuse the c clamps from the stock headers on the installation new Aerocharger header pipes Replace with new c clamps Two 1 4 allen bolts if they are not in good condition they must sit flat inside the manifold flange to prevent exhaust leaks HE 4 Remove the tapered exhaust gaskets and install the flatter gaskets included in the kit
12. re the oil level HORIZONTAL ORIENTATION Oil should be added if the ADD 2 BOTTLES FOR 66 SERIES NOTE NEVER attempt to disassemble the main Aerocharger housings The bearing and vane systems require specialized tools to take it apart without damaging it Contact Aerocharger for all service and repairs www AEROCHARGER com ADD 1 BOTTLE F R 53 SERIES Wess eap DIAPHRAGM lt p al B oitis full at 1 PISTON SHIM height 2 5 cm Z i Use red thread lock fluid on the threads er iy SPRING when replacing the fill plug and tighten i down securely m VISIT AEROCHARGER COM 1 TO SEE A VIDEO TUTORIAL F Housing ABOUT ADJUSTING THE AEROCHARGER S BOOST PN 66078 5i CONTROLLER TO AFFECT INTEGRATED 005 CONTROLLER TURBO RESPONSE The Integrated boost controller on the Aerocharger is a simple mechanical actuator where pressure in a chamber pushes against a spring to move the vanes It can be easily disassembled to adjust the boost by changing springs and or shims Manual amp electronic boost controllers are compatible with Aerocharger systems but are not recommended 913 829 3400 infoajaerocharger com Aerocharger Turbo Systems 10 E FUEL CONTROLLER FITMENT It is important to cleanly route all lines for the turbo system and fuel controller Take care that all lines are located so they will not pinch rub burn or tear Make s
13. roller www AEROCHARGER com 913 829 3400 infoajaerocharger com 5 Harley Davidson FL Series Turbo System Installation Manual IV AIRBOX INSTALLATION 4 Remove the breather fittings from the cylinders and install the included spacers Refit the bolts with blue Loctite and torque to factory spec Then snap the crankcase vent tube assembly onto the breather fittings Run the breather hose along the center frame toward the swingarm 47 INSTALL HERE TO CONN BOOST GAUGE OPTIONAL wA a s j k T k MS o WAN w T d 2 3 es E i 4 2 Using the new throttle body gasket included in the 4 3 Route the boost signal line from the turbo along kit install the Aerocharger airbox onto the motorcycles the center frame and attach it to this fitting on the back of throttle body Use blue Loctite on the threads and torque to the airbox with a small zip tie See Appendix F Carefully 110 inch lbs secure this line along the frame with zip ties taking care not to pinch the line 4 4 Screw the airbox cover into the recess on the airbox with the provided hardware www AEROCHARGER com 913 829 3400 infoajaerocharger com Aerocharger Turbo Systems 6 V CHARGE TUBE NON INTERCOOLED 5 FOR NON INTERCOOLED SYSTEMS Attach the silicone charge tube directly from the turbocharger compressor outlet to the airbox The c
14. ure that the ECM and electrical plugs connect securely It is a good idea to dress all excess line with plastic ties to keep them neat and out of the way Proper fitment will reduce the risk of wear and damage and give the install an OEM appearance x Suggested fitment under the seat for 2008 15 models The stock electronics tray has been notched out to fit the Power Commander unit Several clips have been filed to add space for the ECU bridge connectors Secure all loose wires with zip ties The stock wire tray plastic can be notched to pass the boost signal line through www AEROCHARGER com 913 829 3400 infoajaerocharger com H Harley Davidson FL Series Turbo System Installation Manual SIGNAL LINE ROUTING PICTORIAL WARNING Do not pinch any boost or vacuum line Do not replace vacuum lines with soft rubber lines Secure all lines to their fittings with small zip ties Poor performance or damage can occur when lines are pinched or come loose From the Blow Off Valve connect one arm of the vacuum reference line to the throttle body Connect the other arm to the fuel controllers MAP sensor Run the boost signal line from the turbos controller along the frame directly to the fitting on the Air Plenum A T fitting can be installed into the boost signal line to provide signal for a boost gauge optional www AEROCHARGER com 913 829 3400 infoajaerocharger com

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