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1. raska Aer VENT ng position of vent plug which is also used for replenishing oil level in the Photo showing locatio Installation Manual Page 1 Rev 4 95 BOOST GAUGE INSTALLATION 18 If you purchased a boost gauge suitably mount the gauge in a method of your choosing 19 Route the negative black and positive red to existing sources such that lighting is provided for the gauge when the ignition switch is turned ON 20 The boost hose for the gauge should be routed to the back of the air intake plenum and attached to the existing rubber capped barb Typical boost gauge installation Shown here on the Buell Thunderbolt EXHAUST PIPING INSTALLATION 21 The remaining exhaust piping may now be installed Be sure to place the stainless steel gasket between the exhaust pipe flange and the Aerocharger exhaust outlet 22 Start to draw up the nuts and bolts together 23 The mounting tab on the front exhaust pipe should be placed underneath the bracket on the bike Slide the megaphone bracket into the rubber mount while slipping the flared end over the front exhaust pipe 24 The 2 1 4 stainless hose clamp should be placed around the exhaust pipe and the curved clamping bracket should be mounted on the bike under the transmission end cover 25 Line everything up for a stress free fit before tightening up clamps and brackets Installation Manual Page 1 Rev 4 95 1995 ROAD KING SPEC
2. 5 6 Hose Clamps for Oil Filter Relocation 2 1 2 Washers to space out carb mounting bracket ROAD KING MEGAPHONE MOUNTING HARDWARE 1 Megaphone Pipe 1 2 1 4 Stainless Hose Clamp 1 2 Pipe Clamp Installation Manual Page 1 Rev 4 95 AIR INT AR MANIFOLD REAR VIEW V OPTIONAL di gt GE TO RED DOME e tg BOOST GAL REGULATOR k 2 CONTROLLER ON AEROCHARGER HI LO SWITCH DIAGRAM FOR ALL HARLEY DAVIDSON MOTORCYCLES FINAL CHECKING WARM UP PROCEDURES Thoroughly check over your installation making sure everything is tight You may wish to place a small bead of weather strip adhesive around the outside of the Aerocharger air intake Warm up the rubber air filter neck with a hair dryer Work the neck down over the adhesive on the turbo air intake and then tighten the clamp Thoroughly warm up the engine stop allow to cool and then retighten everything again The use of a thread locking agent is recommended to help keep nuts and bolts tight sure there no fuel leaks when the ignition switch 15 on and the fuel pump is running Remember to warm up your motorcycle every time before riding When the rocker covers are warm to the touch the engine is sufficiently warmed up Extended periods of running the engine without air movement can cause the head retaining studs to be pulled out of the cases This will occur to a stock engine as
3. 39 Install the supplied throttle cables onto the twist grip The cable that has the little spring on it is the throttle closing cable It is installed in the rear opening on the twist grip and runs over the top of the bell crank on the carburetor 40 Push the supplied Aero carburetor onto the intake manifold attaching the choke and throttle cables This carburetor is designed for and is to be used with a stock intake manifold only 85 89 bikes must replace the stock manifold and choke cable with a 90 or newer manifold and choke cable 41 The carburetor is held onto the manifold by the carburetor retention bracket which is already attached to the air intake plenum The bolts used to mount the retention bracket onto the motorcycle are found in the engine breather kit 42 1985 1991 models When mounting the retention bracket place a flat washer onto the bolt place the bolt through the hole in the retention bracket then place the shoulder washer over the bolt with the shoulder facing the bracket so as to fit into the bracket taking up space between the bolt and larger bracket hole For 1992 models please call First Choice Turbo center For 1993 amp newer models see installation s 69 75 on pg 14 at this time for breather kit installation instructions 43 Repeat this assembly procedure for the other bolt and then attach the air plenum and carburetor retention bracket to the motorcycle Installation Manual Page 1 Rev 4 95
4. THE THROTTLE IMMEDIATELY OR SERIOUS ENGINE DAMAGE MAY OCCUR Installation Manual Page 1 Rev 4 95 THE AND ITS FUNCTION The Aerocharger is a unique form of turbocharger which delivers boost faster at lower RPM than any existing form of turbo or supercharging The Aerocharger utilizes air cooled ultra high precision ball bearings to support the exhaust and intake turbine shaft It has a small reservoir of lubricating oil on the intake side of the unit which wicks a very light mist of oil to the bearings There is enough oil contained in the unit for 700 hours of full boost operation This patented ball bearing system is extremely low in friction compared to conventional plain turbo bearings which require large volumes of engine oil for lubrication and cooling It is also very durable and easily passed Mercedes Benz stringent durability requirements Mercedes offers our Aerocharger on its Unimog utility vehicle The Aerocharger controls its boost pressure via a series of moveable wing like vanes inside the cast nickel alloy exhaust turbine The vanes direct the flow of exhaust gas to the exhaust turbine wheel adjusting the velocity of the gas in response to changes in intake air pressure These moveable vanes are continually adjusted by a preset external pneumatic controller On the Harley system the controller is factory preset to deliver 11 11 5 PSI of boost pressure which combined with the recommended ignition tim
5. exhaust flange Temporarily install a couple of bolts to hold the plate and flange in alignment 12 Tighten the front stud nut to hold the Aerocharger mounting plate tight to the engine Photo showing position of exhaust ed to Aerocharger mounting flange Installation Manual Page 1 Rev 4 95 AEROCHARGER INSTALLATION 13 Carefully unpack the Aerocharger and read the WARNING label found on the unit 14 Remove the vent plug located in the top and carefully pour in the special synthetic Aerocharger oil that is included with the unit The Aerocharger now contains sufficient oil for 700 hours of full throttle operation 15 When changing the oil in the motorcycle remove the vent plug and check the oil level in the reservoir with a clean wire When the level drops to 3 4 add oil to a level of 1 1 4 Additional oil can be obtained from your point of purchase Failure to use the special oil manufactured for use in the Aerocharger will void the warranty Note The Aerocharger must be level 16 Remove the shifter linkage cover The linkage rod will have to be flipped over and shortened to 1 1 2 when it is reattached to provide clearance for the Aerocharger The forward shifter needs to be sent to First Choice Turbo Center Inc for modification to clear the Aerocharger 17 Remove the temporary bolts and install the Aerocharger on the mounting plate Be sure to place a stainless steel gasket on both sides of the mounting plate
6. filter relocation bracket may need to have the filter mount holes elongated with a round file or die grinder so the filter will tuck in closer to the frame 58 Remove hard lines and pinch nuts from the oil filter mount Tap both pinch nuts with an 1 8 national pipe thread tap Clean out all shavings from pinch nuts 59 Screw in supplied 1 8 x 1 4 brass barb fittings and tighten 60 Install pinch nuts back into filter mount leaving seals in place Find a 1 1 2 to 2 piece of straight pipe from leftover hard pipe and cut it out Deburr all ends and flare slightly 61 Install remaining brass barb fitting into oil pump outlet Connect supplied 3 8 hose with clamps between oil pump outlet and oil filter inlet 62 The short piece that is flared on both ends is used to go between the end of the hose from the oil sump and the hose you must add to it to go to the oil filter outlet 63 Check all fittings and clamps for tightness Fill a new oil filter with engine oil and quickly attach it to the filter mount 64 The front forks should be pressurized to 12 PSI to provide more resistance to bottoming out IT IS UNDESIRABLE FOR THE FRONT FENDER TO BUMP THE OIL FILTER IN ITS NEW LOCATION ALL EFFORT IS BEING MADE TO HELP YOU PREVENT THIS FROM HAPPENING 65 The crankcase breather kit is used to hold the carburetor onto the intake manifold as well as vent the engine Remove all parts from the breather kit and become familiar with the order
7. happy numbers Some take readings at the crankshaft All torque and horsepower numbers are not created equally i Stock 1340 Evo engines dyno at 60 real ft lb of torque and 50 real hp The Aerocharger on pump gas will safely and reliably double those numbers The most impressive and shocking thing about the Aerocharger dyno readings is the monstrous torque at low RPM This is what Aerocharged Harley riders feel and enjoy when rolling the throttle in fifth gear While it s fun to talk about peak dyno horsepower remember that much of what you read in print is pretend Real gobs of broad Aerocharger induced midrange torque and midrange horsepower are the key to excellent performance 100 120 ft lb of real Aerocharged torque is something few Harley owners have ever felt and those who own one have said that it magnifies many times their enjoyment of what is already a great motorcycle We at FCTC are delighted to share the Aerocharger experience with Harley Evo owners We invite comments and suggestions for improvement Please drive safely and have many years of enjoyment with the Aerocharger With the small 1 1 4 thick intercooler 1340 Aerobikes are averaging 100 115 ft lb and 85 100 hp Installation Manual Page 1 Rev 4 95 TERMS SALE OF AEROCHARGER SYSTEMS AND COMPONENTS AVAILABILITY OF PRODUCTS items will be shipped according to availability on a first come first served basis FCTC will not be responsible for fin
8. in which they will be assembled onto the motorcycle 66 Insert the supplied hollow vent bolt into the mounting hole of the carburetor retention bracket and place one 1 2 washer on the bolt see illustration on page 15 67 Repeat this assembly procedure for the other hollow bolt Both bolts should now be threaded into the cylinder heads hand tight Installation Manual Page 1 Rev 4 95 OIL SUMP OIL PUMP OIL FILTER OIL FILTER MOUNT ADAPTER LATE dia sin BRASS BARB 2 4 gt 1 1 2 2 PIECE OIL PUMP FILTER SYSTEM HARLEY DAVIDSON ROAD KING 1993 amp NEWER MODELS CARBURETOR VENT BOLT RETENTION BRACKET COQ mE es NIPPLE l CYLINDER HEAD RUBBER HOSE 1 2 FLAT WASHER CRANKCASE VENT KIT HARLEY DAVIDSON ROAD KING 1993 amp NEWER MODELS Installation Manual Page 1 Rev 4 95 1 1 1 1 1 1 1 1 1 1 1 3 1 3 5 5 7 3 3 HARDWARE LIST HARLEY DAVIDSON ROAD KING AEROCHARGER SYSTEM Turbo Mounting Plate Harley Davidson Aerocharger 101 Front Header Pipe Rear Header Pipe Turbo Outlet Adapter Front Turbo Outlet Pipe Rear Intercooler Assembly Charge Tube Vortex and Carburetor with cables Air Filter with bonnet Electronic Fuel System 1 1 1 1 1 1 1 1 2 4 Turbo Camshaft Megaphone Pipe with Mounting Hardware Turbo Hardware Kit Oil Filter Relocating and Eng
9. the cases at the base of the front cylinder Replace it with the 5 16 x 4 1 4 stud found in the hardware kit Put on the right hand nut at this time Remove the left nut from the thru stud found running through the cases central to the base of the cylinders Back off the right hand nut on this stud until only one or two threads are left on the end Tap the stud through the cases with a piece of wood hammer handle until the nut is flush on the right side Trial fit the Aerocharger mounting plate on the protruding stud ends on the left side The domed shoulder nut will be used on the end of the stud to mount the Electronic Fuel System The mounting plate should not touch the front cylinder cooling fins If it does care fully file these fins until the mounting plate fits tight to the engine cases with at least an 1 8 air gap between the fins and the plate ed to accommodate Aerocharger mounting plate Photo showing location of the installed Aerocharger mounting plate Installation Manual Page 1 Rev 4 95 EXHAUST HEAD INSTALLATION 9 At this time install the exhaust head piping drawing up the flange nuts evenly uniformly head to head 10 If the turbo flange on the head pipe cannot be lined up with the Aerocharger mounting plate remove mounting plate and bend pipe for alignment with a hammer handle in the flange opening 11 With the plate slack on the studs use punches or dowels to align the plate with the
10. 44 tighten the bolts holding the carburetor retention bracket to the motorcycle 1994 newer motorcycles require the use of the crankcase vent kit to install the carburetor These parts with instructions are found in the carton with the filter relocation kit AN 2 Photo showing carburetor and retention bracket CAUTION ANY ADJUSTMENT ALTERATION OR MODIFICATION OF THE ACCELERATOR PUMP OR PUMP MECHANISM ON THIS CARBURETOR WILL RESULT IN MECHANICAL FAILURE AND POSSIBLE PERSONAL INJURY 45 Locate the supplied length of small diameter black rubber hose Attach one end to the barb located on the very end of the turbo boost controller Route this hose and the small diameter hose coming from the Red Dome fuel pressure regulator to the back of the air intake plenum 46 Push these onto the two hose barbs found on the back of the plenum Be sure all hoses are routed to avoid contact with hot surfaces that could damage them e Use your stock choke cable with the Mikuni HSR 42 carburetor Do not remove the diaphragm located in the float bowl between the accelerator pump rod and piston Installation Manual Page 1 Rev 4 95 INTERCOOLER INSTALLATION 47 Install the intercooler on the front frame tubes with the supplied brackets and hard ware 48 Remove the top bracket from the intercooler and mount it to the motorcycle using the supplied bolt The bracket should be bolted to the front of the motorcycle using t
11. EVOLUTION ENGINE AEROCHARGER SYSTEM INSTRUCTION MANUAL First Choice Turbo Center Inc Installation Manual BEFORE YOU BEGIN UNDERSTAND THE FOLLOWING The Aerocharger is unlike conventional turbochargers It utilizes ultra high precision ball bearings and extremely close tolerances in assembly and orientation TAMPERING WILL VOID WARRANTY IT IS NOT FIELD ADJUSTABLE OR SERVICEABLE NEVER LOOSEN CENTER SECTION CLAMP DO NOT ATTEMPT TO ADJUST BOOST CONTROLLER MODULE CONTROLLER SCREWS DETERMINE VANE SETTINGS NOT BOOST LEVEL The Aerocharger will greatly enhance the performance capabilities of the Evolution engine The Aerocharger greatly increases the torque and horsepower of any engine without lag time normally associated with turbocharging An Aerocharged motorcycle if operated recklessly can experience severe wheel spin and or lifting of the front wheel AEROCHARGED MOTORCYCLES MUST BE OPERATED ONLY BY HIGHLY EXPERIENCED RIDERS Evo Engines and transmissions have proven to have ample strength to handle 120 ft lb of torque Low engine speed is the key to longevity increasing engine speed beyond stock causes engine components stresses to increase as the square of the RPM The Aerocharger allows unprecedented horsepower to be achieved at stock operating speed avoiding high RPM wear and vibration However any high horsepower engine wreak havoc on itself and the motorcycle drivetrain if operated recklessly Powers
12. I style high pressure constant flow fuel pump is utilized which is regulated to about 35 PSI by a brass bypass valve which continually returns excess fuel to the tank via the vent lines connecting the two tank halves A red domed boost sensing final fuel regulator delivers fuel pressure to the carb at between 3 1 2 and 5 PSI higher than boost pressure For example at 10 PSI of boost we need 15 PSI of fuel pressure to ensure smooth fuel delivery This is a proven reliable system that is currently being utilized on over 600 Aerocharged snowmobiles and motorcycles The fuel system and carburetor will flow at maximum enough gasoline to reliably make 110 120 rear wheel horsepower That is why it is hazardous to attempt to override the boost setting of the controller Installation Manual Page 1 Rev 4 95 Too high boost setting will result in high speed lean out and engine damage as well as possible Aerocharger overspeed and destruction ALL AEROCHARGER SYSTEMS ARE DESIGNED TO MAKE RELIABLE TORQUE AND HORSEPOWER RAISING BOOST LEVEL INVITES EXPENSIVE PROBLEMS Anyone desiring to utilize an Aerocharger on a larger than 1340 cc engine should consult FCTC for recommendations THE AEROCAMSHAFT The camshaft supplied with the Aerocharger system is optimum for reliable turbo horse power at stock RPM while delivering excellent fuel economy Stock valve train components are fine The Aerocam allows the engine to generate 10 20 more torq
13. IAL INSTRUCTIONS FOR MOUNTING EXHAUST PIPE 26 Remove the master cylinder reservoir from the frame Remove the right front footboard 27 Install the rear turbo outlet pipe leaving the clamps loose 28 Install the megaphone and tighten both clamps 29 Remount the master cylinder reservoir placing the supplied 3 4 spacers between the frame and reservoir Two 2 1 4 20 x 2 bolts are furnished for this purpose 30 Reinstall the right front footboard placing two supplied flat washers between the frame and footboard the stock bolts are long enough Photo showing installed exhaust pipe 1995 Road King Installation Manual Page 1 Rev 4 95 FUEL SYSTEM INSTALLATION 31 Locate the electronic fuel system This system is mounted on the left side of the motorcycle The top is attached using the horn mount The bottom is located over the central case stud that sticks through the rear hole of the Aerocharger mounting plate You will have to find another place to mount the horn 32 For Hi Lo switch installation drill a 1 2 hole in the raised lower left part of the fuel sys tem cover about 1 2 from the bottom Locate the Hi Lo switch in this location such that the bleed orifice is facing up This will be Hi with the switch up 33 Splice the T into the small rubber hose coming from the boost controller Do not alter the length of the hose between the switch and the T See diagram on Page 16 34 Viewing the electr
14. WISE TO FOLLOW HARLEY S BREAK IN PROCEDURE BEFORE OPERATING THE ENGINE UNDER BOOST AFTER ENGINE BREAK IN WE SUGGEST THE USE OF EITHER AMSOIL 20W 50 OR MOBIL 1 15W 50 SYNTHETIC OIL The Aerocharger is not yet certified by the GARB and like all other engine carburetor exhaust system modifications is not currently legal for use on California highways It is currently being sold for off road use only Other states may have similar regulations every user should check local state ordinances regarding on highway use All Aerocharger system installations should be done by a trained professional mechanic Consult HD Service Manual for camshaft installation instructions Installation Manual Page 1 Rev 4 95 TORQUE AND HORSEPOWER The Harley Davidson aftermarket industry thrives on the power of exaggeration It s tough for the consumer to make intelligent decisions when it comes to increasing the performance of the Evo engine The Aerocharger will forever change the world of Evo performance We have spent countless hours testing components on what has become the industry standard the DynoJet rear wheel inertia dynamometer Measuring the torque and horsepower at the rear wheel the DynoJet computer uses the conservative SAE correction factor which estimates how much power the engine will make at 77 F at 700 ft above sea level Some dyno testers use more optimistic standard correction factors some even calibrate their dynos to read
15. ancial losses due to delayed shipments BACK ORDER POLICY Out of stock orders will be held until products are available Purchaser will be notified prior to shipment Back orders will receive priority over new orders METHODS OF PAYMENT There are no open accounts All shipments will be made with payment in advance by check allow one week to clear Visa MasterCard or C O D cash or certified check C O D purchasers will be notified prior to shipment so that cash or certified check can be made available foreign orders must be prepaid METHODS OF SHIPMENT UPS is our preferred carrier but FedEx US Postal Service or any other carrier of your choice can be used PRICES amp PRODUCT SPECIFICATIONS Prices listed in our catalog do not include shipping and handling charges which are added to each invoice All prices subject to change without prior notice NY residents must pay the appropriate sales tax Minimum order requirement is 50 00 Prices materials design and specifications are subject to change without prior notice merchandise information presented in the catalog was true and correct at time of publication RETURN POLICY No items may be returned without prior authorization returns are subject to a 30 restocking fee Customers refusing shipments will be liable for freight and handling charges in addition to the 30 restocking fee Items being returned for repair or replacement must be accompanied by a Return A
16. he existing tapped hole found in the frame junction plate adjacent to the fork locking lug 49 Attach the top of the intercooler to the upper bracket using the supplied rubber mount Taking note of how it is positioned on the mount remove the pipe clamp from the lower intercooler mount 50 Spread open sufficiently to slip over the right frame down tube Pinch back together and reattach to the intercooler in the same position 51 Connect the intercooler to the Aerocharger with the 22 silicone hose and two damps supplied 52 Connect to the air intake plenum with the chrome air pipe and accompanying sili cone hoses and clamps 53 Check the position and alignment of the intercooler and air pipe before tightening the intercooler mounts and hose clamps to motorcycle frame Installation Manual Page 1 Rev 4 95 OIL FILTER amp CRANKCASE VENT INSTRUCTIONS FOR THE 1993 AND NEWER HARLEM DAVIDSON ROAD KING MODELS 54 After positioning a suitable drain pan remove the oil filter 55 Following the pipes back from the oil filter mount unscrew the pipe from the pump Unclamp and pull the hose off of the end of the other pipe 56 Unbolt and remove the oil filter mount from the motorcycle 57 Mountthe filter relocating plate under the rectifier so that the filter mount is on the driver s left side The filter mount bolts to the relocation plate so that after the filter is screwed on it is above the rectifier The oil
17. hifting leaving the throttle wide open as the gears are changed an Aerocharged engine will eventually destroy the clutch transmission and or final drive and may cause engine damage by running against the rev limiter for extended periods of time ROLLING OFF THE THROTTLE WHILE SHIFTING IS HIGHLY RECOMMENDED It is recommended if you have a new bike to break it in at least 1 000 to 1 500 miles before installing this kit If you are unable to resist the temptation of installing your Aerocharger system before the break in period we recommend that you hone the cylinders 0025 0030 over to provide adequate clearance for piston growth High horsepower engines require premium grade gasoline Aerocharged Evo engines require 92 octane unleaded gasoline at sea level to prevent detonation at 11 PSI of boost Higher altitude riding requires 90 octane We have logged over 20 000 sport riding and touring miles on our Aerocharged Evo engines with zero detonation Lower octane can be used for cruising but periods of operation on boost should be restricted to short bursts Due to size restrictions Aerocoolers charged air intercoolers are not intended for continuous duty at full boost After 8 to 15 seconds depending on model Aerocooler efficiency will drop and detonation resistance will be diminished High ambient temperatures and heavy loads make octane requirements more stringent ANYTIME AUDIBLE PINGING IS HEARD OR POWER BEGINS TO FADE LET OFF
18. in the fuel tank and remove Remove the carburetor and control cables from the motorcycle Remove all exhaust system piping Remove the stock CDI unit and install the Dyna 2000 in its place switches on this ignition should be placed in the OFF position The only exception to this would be if you are using a Single Fire ignition system that has two coils In this instance switch number six 6 should be turned ON This electronic ignition requires that the VOES switch be fully operational 2 Install the Aero camshaft following the instructions found in your Harley Davidson service manual While installing the camshaft install the headgaskets supplied with this kit Refer to your Harley Davidson Service Manual for instructions 3 Ifthe oil filter on your motorcycle is located in the front of the engine it will require relocating Find the box in your kit that contains the items necessary for relocating the oil filter Follow the instructions included with these items 4 If your motorcycle is a 1994 or newer model a non vacuum fuel petcock must be installed in your fuel tank in place of the vacuum type see photo below You may obtain this from your Harley Davidson dealer Specify a non vacuum petcock 1992 or earlier Photo shows installation location of non vacuum petcock Installation Manual Page 1 Rev 4 95 AEROCHARGER MOUNTING PLATE INSTALLATION 5 6 7 8 Remove the 5 16 bolt found running through
19. ine Breather Kit 1993 and newer only Instruction Manual Dyna Ignition with Adapter Harness Hi Lo Switch Premium Head Gaskets with Fire Rings 1995 and Later Road Kings 3 4 Aluminum Spacers and 2 x 1 4 20 x 2 Bolts for spacing out master cylinder reservoir Washers for spacing out right footboard ROAD KING TURBO HARDWARE KIT 8mm x 25mm Bolts 8mm x 35mm Bolt 10mm x 25mm Bolts 8mm Nuts 8mm Lock Washers 8mm Flat Washers 10mm Flat Washers 10mm Lock Washers Installation Manual 1 1 1 1 2 1 5 16 Chrome Acorn Nut for Turbo Mount Plate 5 16 4 1 4 Stud used to replace case stud for front hole in turbo mounting plate Turbo Exhaust Inlet Gasket 24 of 1 8 Norphene Hose 6 Wire Ties Turbo Inlet Gasket Domed Shoulder Nut goes on 5 16 x 4 1 4 Stud to hold Electronic Fuel System lower mount Page 1 Rev 4 95 ROAD KING INTERCOOLER KIT 1 Intercooler 2 5 16 Chrome Acorn Nuts 1 19 Strap Clamp 2 1 Rubber Mounts 4 x 5 16 Flat Washers 2 5 16 x 3 4 Bolts 4 x 5 16 Lock Washers ROAD KING OIL FILTER RELOCATING amp ENGINE BREATHER KIT 1 42 of 3 8 Oil Hose 1 Crankcase Breather Filter 1 Oil Filter Mount Relocating Bracket 1 Crankcase Breather Hardware Pkg 2 8mm x 25mm Bolts 2 x hollow bolts 2 8mm Nuts 2 x breather nipples 2 8mm Flat Washers 2 x sections of rubber hose 1 Coil of Crankcase Breather Hose 3 1 8 x 1 4 Brass Barb Fittings
20. ing allows the stock 1340 Evo engine to operate powerfully and reliably on premium grade unleaded pump gasoline The model 101 200 Aerocharger supplied with the Harley system has the capacity to flow only enough air to efficiently make 110 120 rear wheel horsepower Raising the boost to a higher level invites turbine over speed and damage high intake charge temperature and poor performance Larger Aerochargers are available from FCTC for custom applications THE FUEL SYSTEM The 42mm Mikuni turbo carburetor is calibrated specifically for the Aerocharger Adjusted properly it will provide instant burble free throttle response while delivering excel lent touring fuel economy We have operated our Aerocharged bikes from sea level to 6000 ft and had crisp burble free performance Carburetors deliver the correct amount of fuel to the engine by sensing what is referred to as pressure differential between the float and the venturi area inside the throat of the carb The Aerocharger carb has its float bowl vents pressurized by boost pressure During operation on boost the pressure in the high velocity venturi area is slightly lower than the float bowl area and the fuel is forced up the needle Jet into the venturi Because the float bowl area is pressurized standard gravity feeding the gasoline into the carb will not work The Aerocharger carb has a smaller 1 5mm needle and seat and is kept full by a unique boost sensing fuel system An EF
21. onic fuel system from the top a length of hose with a T on its end will be found coming from the gold colored unloader valve The T end of this hose goes on the fuel tanks cross connect fittings found on the lower front area of the fuel tanks Photo showing location of Hi Lo switch 35 The fuel hose that passes through the rubber grommet on the top of the fuel system is to be attached to the non vacuum fuel petcock on the fuel tank 36 The remaining fuel hose coming out from the back of the fuel system goes to the carburetor fuel inlet Secure all hoses with the supplied hose clamps before energizing the fuel system 37 The smaller hose that is found coming from the Red Dome fuel pressure regulator should be routed between the cylinders and over to the carburetor It will be pushed onto a hose barb on the back of the air intake plenum See diagram on next page Installation Manual Page 1 Rev 4 95 38 The electric fuel pump should run when the ignition switch is in the ON position not accessory If this does not happen find a terminal that will activate the fuel pump when the ignition switch is ON and attach the wire there Failure to do this WILL result in severe engine damage NOTE DO NOT LEAVE FUEL PUMP RUNNING WITH FUEL PETCOCK IN THE OFF POSITION DOING SO WILL CAUSE OVERHEATING OF THE FUEL PUMP AS WELL AS FUEL PUMP FAILURE Photo showing location of terminal block and wiring CARBURETOR INSTALLATION
22. ue and horsepower at 11 PSI of boost Stock camshaft timing is very acceptable with the Aerocharger but engine output per pound of boost will be slightly lower OPERATION OF THE AEROCHARGED EVO ENGINE As is discussed in the instruction manual engine warm up is extremely important to maintain the integrity of the head gaskets and to preheat the Aerocharger a bit One unique feature of the Aerocharger is its ability to build instant boost It will truly amaze those familiar with turbochargers when four or more PSI of boost appears when blipping the throttle in neutral Full boost will not be observed until the engine is under load Driving the Aerocharged motorcycle is no different than driving a stocker Acceleration however is achieved at an extremely rapid rate and extreme caution must be exercised When cruising at the legal speed limit in high gear some boost pressure will be observed which is nor mal It would however be wise to avoid lengthy periods at high boost the standard 1 25 thick Aerocooler is designed for intermittent use during touring and sport riding and it is possible to exceed its cooling capacity When that occurs intake charge temperature will climb power will drop and detonation resistance will be reduced Anyone wishing to operate at high engine loads for extended periods of time should consult FCTC for Aerocooler upgrades and advice ALWAYS PURCHASE THE HIGHEST POSTED OCTANE GASOLINE AVAILABLE IT IS ALSO
23. uthorization R A number along with an explanation of problem TECHNICAL SUPPORT INFORMATION Technicians are usually available at XXX XXX XXXX during normal working hours EST to help address installation or tuning difficulties SHORTAGES amp WARRANTIES Any shortages from the parts list must be reported within three days AIl Aerocharger system components carry a sixty day replacement or repair warranty from date of purchase Warranty will cover Aerocharger system components only difficulties with engine or chassis arising from the use of the Aerocharger are solely the responsibility of the purchaser FCTC will not pay any labor or towing expenses arising from the failure of any system components Installation Manual Page 1 Rev 4 95 HARLEY DAVIDSON ROAD KING AEROCHARGER SYSTEM INSTALLATION INSTRUCTIONS Congratulations on your purchase of a First Choice Turbo Center Aerocharger system for your motorcycle Proper installation and operation will give you the acceleration of a stroker with the cruisability of a stocker Please inspect the contents of your Aerocharger kit Become familiar with all items and check them off against the contents list found in this book Please contact your point of purchase if you have found any discrepancies All kits are double checked prior to shipment Installation Manual Page 1 Rev 4 95 INSTALLATION PREPARATION 1 Ina well ventilated area free of fire and spark hazards completely dra
24. well as a modified engine The cylinders will get hot and swell stretching upwards with sufficient force to pull out the studs if the engine is allowed to run for extended periods of time The management and staff at FIRST CHOICE TURBO CENTER INC wish you many years of enjoyment with your Aerocharged motorcycle Installation Manual Page 1 Rev 4 95 Appendix 1 Specs PART NO DEMOS21 GRIND NUMBER FCTC 1 ENGINE DENT 1984 UP HARLEY DAVIDSON V 2 80 CU IN ur 312 3125 rns 35 BTDC i BBDC CRANE CAMS INC 530 FENTRESS BLVD DAYTONA BCH FL 22114 904 258 6174 Installation Manual Page 1 Rev 4 95

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