Installation Instructions
Contents
1. in this matter There will be no exceptions to this policy Return Policy Procedure 1 There will be NO CREDIT TO YOUR CREDIT CARD ACCOUNT OR CASH REFUNDS Your monthly statement will NOT show any credit when you return an item Your account with Trask Performance will be issued a credit for merchandise or exchange for the same value 2 All returns MUST HAVE A PRIOR AUTHORIZATION NUMBER 3 A RETURN AUTHORIZATION NUMBER AND A COPY OF THE INVOICE must accompany all returns Returns will not be accepted without return authorization 4 Parts authorized for return must be in original packing only ABSOLUTELY NO SUBSTITUTIONS WILL BE ACCEPTED 5 Parts that were originallv shipped in vendor plastic bags boxes or shrink wrapped must be returned in that original packing and condition No writing of anv kind is permitted on original supplier packages or boxes Defaced items will be returned to customer NO SUBSTITUTIONS WILL BE ACCEPTED 6 Trask Performance must be contacted within 10 davs for anv returns or problems NO RETURNS ACCEPTED AFTER 30 DAYS 7 If the return is NOT the error of Trask Performance there will be a 20 RESTOCKING FEE Thank vou for vour cooperation 21601 N 3F Ave Ste D Phoenix AZ 85027 623 879 8488 main 623 879 8470 fax TurboYourHarley com WARRANTY NO WARRANTY ON PERFORMANCE WORK We warranty products to be free in defects in material or workmanship for 12 months from purchase date In the event2. stop screw until TPS voltage reads 45 volts Reset IAC and double check IAC steps Should be around 30 80 steps when fully warmed up Idle should not drop below 1 000 rom Oil feed to turbo may become insufficient 2 Lack of power Check BOV on front of surge canister Make sure valve is sealing Check for leaks in canister cracks etc Check fuel pressure Needs around 50 60 psi to operate correctly 3 Heavy Surge Bucking when at cruise Check map signal Make sure vacuum line is installed on map sensor Call Trask Performance for remedy 4 Smoking out tailpipe Make sure turbo drain hose is not restricted kinked Call Trask Performance Tech Support NOTE MAKE SURE NGK DCPR9E SPARK PLUGS ARE INSTALLED WITH THIS SYSTEM AND GAPPED TO 034 ENGINE DAMAGE OR SPARK PLUG FAILURE MAY OCCUR IF CORRECT SPARK PLUGS REFERENCED ABOVE ARE NOT INSTALLED ITITWARNING ITI THIS PRODUCT IS FOR OFF ROAD USE ONLV e EACH ENGINE IS DIFFERENT AND MUST BE DVNO TUNED AFTER INSTALL IF YOUR DYNO TECHNICIAN HAS ANY QUESTIONS PLEASE CONTACT RON OR NICK AT TRASK PERFORMANCE 623 879 8488 21601 N3 Ave Ste D Phoenix AZ 85027 623 879 8488 main 623 879 8470 fax TurboYourHarley com RETURN POLICY Dear Valued Customer We at Trask Performance have found it increasingly difficult to return parts to our suppliers It is now necessary to tighten our own Return Policy and need your full cooperation
3. Delphi Injected FL Dvna Sottail Turbo Kit Installation lt The following procedures should be followed in the order they are listed to avoid extra work The installation should take 8 10 hours The tools you will need are standard hand tools Included in the kit are all necessary drills and taps needed for the installation Footnotes are provided to help with additional problems you might encounter lt Trask Performance has designed the TRASK turbo system to provide usable dependable horsepower for many trouble free miles It was intended to make 8 lbs of boost on 91 or higher octane fuel At this level the bike should make 110 horsepower If the customer chooses to increase the boost level the fuel system will have to be tuned and other modifications may be needed to supply enough fuel for higher levels of performance Also engine modifications may be needed to support higher levels of horsepower Trask Performance does not recommend raising boost levels beyond the kit preset levels unless you make the proper modifications Expensive engine damage may result if these warnings are not observed With that said lets get started lt If you increase boost level above the kit settings the bike will need to be tuned to insure the engine doesn t run dangerously lean resulting in engine damage NOTE For maximum power we recommend having the bike dyno tuned to achieve maximum power potential Air fuel ratio should be set around 13 5 cruise a
4. e the regulator Step 14 Install the fitting with red loctite on the threads Plug the modified unit from the housing and tap the regulator back into its housing with the boost port fitting in line with the fuel line atmosphere port with the 10 32 Towards the rear of the bike Reassemble the fuel pump assembiv Connect tap from the hardware kit the supplied 1 8 pollv line from the black head fitting to the boost regulator fittina Step 15 Be sure the line is long enough so it won t crimp Secure the fuel pump access plate back onto the fuel tank Route the boost line to the front of the tank then to the canister Use the anti abrasion sheath to protect the line from chafing and heat Connect to the canister Reinstall the dash Step 16 Remove the oil pressure Step 17 There are two holes taped switch install the aluminum adapter into the adapter the 1 4 NPT should with thread sealer point down and the 1 8 NPT should point up Install the oil pressure switch with thread sealer on the bottom side and the 1 8 NPT 3 AN on the top Step 18 Remove from your old exhaust systems 2 exhaust Step 19 Install the oil drain line on to the cam cover fitting flanges and 2 retaining rings Install onto the Trask Turbo first as it will be easier to get to Bolt the turbo onto the header Apply some ultra copper RVT silicone inside the slip fit header loosely Install supplied 4 Bolt Gasket Do not to seal Put exhaust clamp provided on the
5. ld with new intake seals Provided in the kit Step 4 Remove the cam cover Re install supplied cam cover and new gasket Step 5 Remove dash Unplug Step 6 Remove the fuel pump Step 7 Lift the pump assembiv out of the fuel pump connector and access plate the tank enough to remove the bail overflow hose Start the engine to clip Hold on to the tab that the clip release the fuel pressure connects to otherwise it will fall into the tank Step 8 Disconnect the regulator from Step 9 Remove the pump assembiv from the tank Disconnect the filter Vou don t need to remove anv the wires from the plug Remove the bail spring and separate fuel lines or clamps Pull the regulator the pump section from the plate section assembiv from its housing Step 10 Measure 9 32 from the edge of the stamped Step 11 Drill a small pilot hole then enlarge to 13 32 section This is where vou will need to drill for the bulkhead Install the bulkhead fitting with the 907 end and the o ring fitting Be sure not to be any further away from the washer on the outside Applv some thread sealer to the stamped section otherwise it will interfere when vou threads on the fitting Do not over tighten the plastic nut on reassemble the pump assembiv the inside Step 12 On softail models locate position for drilling bv looking at photos Also make sure when lowering the dash that the fitting and boost line don t interrupt the speedo housing Step 13 Remov
6. line into canister over the three bolts Align the pen canister with the 2 dia 90 silicone the manifold vacuum port Install the marks and tighten the set screw Next elbow Trim to fit if needed air filter install the cover with the gasket Make sure everything is connected and tight check to see whether hoses have clearance from the exhaust Top off the oil and start the engine Check for exhaust leaks and oil leaks After everything is double checked and the engine is started take a short ride and check for loose connections Now you need to load the fuel map supplied with the kit Maps for both Power Commander and Race Tuner are provided The bike should be dynotuned for optimum power TRASK PERFORMANCE MAKING FAST BIKES FASTER 623 879 8488 150 TENORON DI Max POWER 1250 4 20 sheer eee e urbogharged fora A 120 110 pU Max a an 3 110 o 100 100 m z 90 90 o p 80 4 BID E gt 70 sab ao I 60 60 L x 50 50 d P 40 40 30 30 20 t 20 15 20 25 30 35 40 45 50 55 60 6 55 RPM x1000 NOTE If you plan to drag race your bike we recommend using 100 Octane fuel Trouble Shooting The following is a trouble shooting guide for our Delphi turbo kits 1 When on start up bike won t idle below 2 500 rpm Check intake leaks Check IAC function Reset IAC with Scanalyzer Make sure throttle plate fully closes Check TPS voltage If set too high above 55 volts back throttle
7. nd 12 8 13 0 for power Running to lean will result in temperature increase and engine damage may occur DELPHI INJECTED FL DYNA SOFTAIL TURBO KIT INSTALLATION PROCEDURES Make sure you have a Service Manual for your model and year bike before you start Remove your gas tank It is much easier to work on the intake Also make sure you remove the fuel pump fuse or unplug the fuel pump connector and start the engine and let it run out of gas Step 1 Remove the exhaust system air Step 2 Remove outer primary cover and filter and backing plate Remove and install the performance clutch spring as discard your spark plugs Install the plugs per factory manual procedures Adjust supplied in the kit gap 032 and use anti clutch cable per manual Replace gaskets seize on threads and re install with new primary oil Step 3 Remove throttle body Before you install the new fuel injectors you will need to drill and tap the bottom side of the manifold Just above the part number center punch and drill with the 21 drill bit supplied in the kit Now tap with the 10 32 tap also provided in the kit Blow out all metal chips and shavings Apply red thread lock to the threads of the fitting and install Snug the fitting to the manifold Do not over tighten You don t want to strip the fine threads Install the vacuum line Secure the vacuum line with a cable tie on the fitting Install the new fuel injectors Re assemble the throttle body manifo
8. of such a defect within the warranty time period we will at our discretion replace or recondition the product at no charge We shall not be responsible for any costs including but not limited to costs resulting from labor charges shipping charges delays vandalism negligence fouling caused by foreign materials damage from adverse air or weather conditions chemicals or other circumstances over which we have no control This warranty shall be invalid by any abuse misuse misapplication or improper installation of these products Products not manufactured by Trask Performance are covered under the manufacturer s warranty These products contain their product warranty in the package Please contact the manufacturer for warranty claims The installation of some aftermarket products may void your vehicle warranty ALL SALES ARE FINAL TRASK BOOST GAUGE KIT INSTRUCTIONS Remove 2 x clutch perch clamp bolts Using original washers and supplied longer bolts install gauge mount Install gauge into mount adjust and gently lock down set screw to hold gauge in mount Route 1 8 plastic boost line from gauge along side of handlebar down to pressure source port Trask V Rod system has a port on front of plenum Use adapter supplied in the kit to attach pressure line to pressure port fitting
9. slip fit and assemble tighten until next step Install the oil drain line onto the the header Install the header on the engine and use the 4 new cam cover fitting then install the drain adapter on the other exhaust nuts provided Tighten the pipe to the heads only end Secure the drain adapter onto the turbo last Tighten enough to hold with enough movement to align the system later the hose clamps This may be a really tight fit Step 20 Install tailpipe with gasket Step 21 Secure the tail pipe to the bag Step 22 Route the oil feed line Start the 5 socket head bolts onto the support bracket Longer bolts and spacers behind the turbo and connect both turbine housing Before tightening the are provided in the hardware pack Install ends one on the turbo and the other socket head tail pipe bolts start the 3 8 the tail pipe heat shield on the oil feed adapter tail pipe to header support bolt Tighten all the hardware on the tail pipe then the turbo to header bolts Step 23 Install the oil mister Step 24 Replace your stock throttle Step 25 Start by installing the front hex breathers use red loctite Check body to air cleaner gasket seal and head support bolt then the three 1 4 20 clearance from the canister install the canister Use blue loctite on socket head bolts and gasket then the the support bolts rear support bolt Step 26 Place the velocitv stack into the Step 27 Connect the turbo to the Step 28 Plug the blow off
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