INSTALLATION - Kuryakyn USA
Contents
1. i E INSTALLATION PRODUCTS HYPERCHARGER FOR TWIN CAM 9752 CUSTOMER SERVICE CHROME BODY WITH CANDY BLUE BUTTERFLIES AND TRAP DOOR FITS 99 UP TWIN CAM WITH CV CARBURETOR AND 06 UP TWIN CAM WITH DELPHI EFI INSTALLATION QUESTIONS PART INCLUDED Chrome Hypercharger Assembly Trap Door Candy Blue LIMITED WARRANTY Butterflies Candy Blue Support Bracket Breather Hardware Kit including 1 1 4 Breather Bolts pr Breather Hoses pr Shim Washers 0 030 thickness Twin Cam Breather Kit Including Breather Adapter Spacer 90 Barbed Fitting 1 8 NPT 180 Barbed Fitting 1 4 28 16 Vacuum Hose Barbed T Fitting 1 4 20 x 1 1 2 SHCS Patched Gasket with Adhesive Gasket without Adhesive 4 Nylon Cable Ties Delphi Vacuum Adapter Installation Instructions 408332 909975 9920 909999 AN gt oS es fy Sa Ss es KR So Se pe et Please read and understand entire instructions before starting installation THANK YOU FOR CHOOSING KURYAKYN WARNING THE POSSIBILITY OF CONTACT BETWEEN THE HYPERCHARGER AND THE FUEL TANK EXISTS ON 06 LATER DYNA MODELS THE FOLLOWING STEPS MUST BE TAKEN DURING INSTALLATION TO ENSURE ADEQUATE CLEARANCE e Apply downward pressure to the right front cylinder side of the support bracket as the breather bolts are tightened At the same time you must ensure ABOUT OUR CATALOG that the three 1 4 20 threaded holes in the throttle body line up with the correspondin2. all the rubber manifold air pressure seal onto the adapter body See PIC 3 Install the vacuum adapter on the MAP sensor Be sure the orientation of the hose barb is correct See PIC 4 next page i IAC BRACKET STEP 6 Remove the IAC bracket HOLD DOWN ph IAC UNIT remove the MAP sensor See PIC 2 PIC 3 IAC UNIT FASTENER PLATE VACUUM ADAPTER cont PAGE HYPERCHARGER INSTALLATION MANIFOLD AIR PRESSURE SEAL STEP 8 Install the IAC bracket on the throttle body DO NOT tighten the fasteners yet Be sure the ee peg on the bottom of the MAP sensor fits into the alignment hole on the throttle body See PIC 5 Kurvakyn STEP 9 Insert the MAP sensor assembly into the throttle body The vacuum PIC 4 adapter body fits under the tab on the IAC bracket Be sure the orientation of the hose fitting is correct See PIC 6 Tighten the fasteners on the IAC bracket 1 MAP SENSOR oe STEP 10 Connect one end of the vacuum hose included with the Hypercharger to the hose fitting on the vacuum adapter STEP 11 Connect the wiring harnesses to the MAP sensor and the IAC unit STEP 12 Reconnect the throttle and idle cables and cruise control if fitted Install the air cleaner fuel tank and seat refer to your factory service manual for ihe specific instructions HOLD DOWN PLATE EO Z Oo O O STEP 13 Position the chrome support bracket over the mouth of the throttle body and f
3. asten loosely to each head with the supplied breather bolts CAUTION BE SURE THE SUPPORT BRACKET IS FULLY SEATED AGAINST a THE HEADS AND THAT THERE IS NO GAP USE THE e F SUPPLIED SHIMS AS NEEDED A GAP WILL RESULT IN A BROKEN SUPPORT BRACKET STEP 14 Slide an intake gasket between the support bracket and the throttle body mouth be sure all the holes are aligned Tighten the breather bolts a i A STEP 15 Trim 1 4 from each end of ONE of the supplied breather hoses NENT b Install this hose between the front head and the 90 fitting on the breather adapter PIC 6 STEP 16 Install the remaining breather hose between the rear breather bolt and the straight barbed fitting on the breather adapter Secure the ends of the two hoses with the supplied cable ties trim the cable tie ends See PIC 7 TAB ON IAC BRACKET STEP 17 Remove the paper backing from the self adhesive intake gasket and apply the gasket between the Hypercharger and the breather adapter Be sure to align the holes STEP 18 Use an 1 8 Allen wrench to remove the trap door from the Hypercharger STEP 19 Install the three supplied 1 4 SHCS into the Hypercharger mounting holes VACUUM ADAPTER STEP 20 While holding the gaskets in place between the breather adapter support bracket and air cleaner secure the assembly to the throttle body DO NOT over tighten the fasteners hand tight plus 1 4 turn with a wrench is sufficient torque to secur
4. e the fasteners STEP 21 Replace the trap door on the T i Hypercharger Connect the vacuum line to the air jet any p A i on the bottom of the Hypercharger vacuum pod cont HYPERCHARGER INSTALLATION FOR CARBURETED MODELS ONLY PROCEDURE Kurvakun STEP 1 Remove the stock air cleaner assembly PIC 8 STEP 2 Use needlenose pliers to remove the vacuum hose from the vacuum tap on the rear of the carburetor See PIC 8 This step may require the removal of the carburetor from the intake manifold consult your factory service manual STEP 3 Cuta 1 1 2 length of vacuum hose from the vacuum hose provided Connect the vacuum lines to the barbed T fitting as shown in PIC 9 Reconnect the vacuum line assembly to the carburetor as shown in PIC 10 STEP 4 Ifthe carburetor was removed in STEP 2 reinstall it now Be sure the carburetor is fully seated in the manifold wetting the rubber seal may make this easier STEP 5 Position the chrome twin cam mounting bracket over the mouth of the carburetor and fasten loosely to each head with the stock breather bolts CAUTION BE SURE THE SUPPORT BRACKET IS FULLY SEATED AGAINST THE HEADS AND THAT THERE IS NO GAP USE SHIMS AS NEEDED A GAP WILL RESULT IN A BROKEN TWIN CAM SUPPORT BRACKET STEP 6 Slide an intake gasket between the support bracket and the carburetor mouth be sure all the holes are aligned Rotate the carburetor in either direction to align the holes Tighten the breath
5. er bolts STEP 7 Trim 1 4 from each end of ONE of the supplied breather hoses Install this hose between the front head and the 90 fitting on the breather adapter STEP 8 Install the remaining breather hose between the rear breather bolt and the straight barbed fitting on the breather adapter Secure the ends of the two hoses with the supplied cable ties trim the cable tie ends See PIC 11 STEP 9 Remove the paper backing from the self adhesive intake gasket and apply the gasket between the Hypercharger and the breather adapter Be sure to align the holes STEP 10 Use an 1 8 Allen wrench to remove the trap door from the Hypercharger STEP 11 Install the three supplied 1 4 SHCS into the Hypercharger mounting holes note that the hole in the 10 o clock position is the float bowl vent do not use this hole STEP 12 While holding the gasket in place between the breather adapter and support bracket secure the assembly to the carburetor Do NOT over tighten the fasteners the aluminum will strip easily STEP 13 Replace the trap door on the Hypercharger Connect the vacuum line to the air jet on the bottom of the Hypercharger vacuum pod STEP 14 Check for proper throttle operation Ride On HYPERCHARGER INSTALLATION
6. g holes in the support bracket e Rotate the Hypercharger assembly clockwise and down as the three 1 4 20 x 1 1 2 socket head cap screws are tightened to provide maximum fuel tank clearance e Immediately after installation verify there is adequate clearance between the Hypercharger assembly and the tank with motorcycle at idle and under load NOTE KURYAKYN WILL NOT BE HELD RESPONSIBLE FOR ANY DAMAGE CAUSED BY FAILURE TO ENSURE PROPER CLEARANCE CAUTION The installation of any high performance air cleaner and or exhaust system can cause a lean fuel air mixture A lean fuel air mixture can cause engine overheating resulting in severe engine damage Kuryakyn recommends having the motorcycle tuned by a competent technician cont 9752 15HD 0407 ATTENTION A factory service manual is necessary for performing this installation Do not attempt to perform this installation if you are not confident in your ability to complete all steps in the 0 0 procedure consult a trained technician Kurvakyn PIC 1 NOTE It is the installers responsibility to make sure all fasteners including pre assembled are tightened before operation of motorcycle K ryakyn will not warranty components that are lost due to improper installation Periodic n maintenance may be required NOTE Some of our high performance air cleaners extend beyond the stock OEM unit to achieve smoother air flow and better performance Riding positio
7. n may be affected eo FOR 06 UP FUEL INJECTED MODELS ONLY fae LEFT SIDE NOTE The following photos show the throttle body removed STABILIZER LINK FIG 1 from the motorcycle for clarity You DO NOT have to remove the throttle body to perform this installation RIGHT SIDE PROCEDURE STEP 1 Remove the seat and fuel tank refer to your factory service manual for specific instructions STEP 2 Remove the air cleaner refer to your factory service manual for specific instructions STOCK LOCATION STEP 3 Remove the throttle and idle cables and cruise control cable if fitted refer to your factory service manual for specific instructions STABILIZER LINK 1 1 2 gt BOLT lt _ BOLT lt FRAME ae WASHER STEP 4 For FXD models only On Dyna models there is not adequate clearance for the MAP sensor after the vacuum adapter is installed You must remove and reposition the stabilizer link hardware to allow sufficient clearance for the MAP sensor Locate the stabilizer link between the frame and the motor mount See PIC 1 Remove the stock hardware and re install in the new location following the diagram in FIG 1 SPACER MOTOR MOUNT NUT NUT NEW LOCATION STEP 5 Remove the two wiring harnesses going to the MAP manifold air pressure sensor and the IAC idle air controller unit STEP 7 Assemble the vacuum adapter Inst
Download Pdf Manuals
Related Search