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1. DARING ee ee PRODUCTS PRO SERIES HYPERCHARGER FOR ROAD STAR 9421 FITS 99 04 ROAD STAR 1600 AND 1700 EX WARRIOR INSTALLATION E MAIL techsupport kuryakyn com PART INCLUDED or call 715 247 2983 600185 1 Chrome Pro Series Hypercharger WARRANTY 909420 1 Mounting Kit Containing the Following Seventeen Items a nla eel shoe sold hereunder if properly installed maintaine 200100 3 1 4 20 Nylock Nut and operated re einen shall be free 200150 3 1 4 20 X 5 8 Socket Head Cap Screw Patched from any defects in materials and workmanship 200373 1 M6 Serrated Flange Nut for a period of one 1 year from the date the K ryakyn products are sold to the customer 200422 4 M4 7mm x 10mm Socket Head Cap Screw E RGES 200450 2 M6 1 0mm x 30mm Socket Head Cap Screw K ryakyrr shall not be liable tonany 200486 2 M6 1 0mm x 16mm Socket Head Cap Screw consequential or incidental damages 401162 3 M6 Tapered Bolt Caps 400086 16 5 32 Vacuum Line ABOUT OUR CATALOG 400859 1 3 Way Barbed T Fitting You ll find all our innovations for H D GL and Metric Cruisers i r catalogs Order onli 400325 1 90 Degree Elbow e a epranle 400598 1 Rubber Intake Duct product comes with a Proof of Purchase good for a 400811 1 Barbed Connector 3 8 complimentary catalog Details in packaging 401016 1 Main Support Bracket Be sure to ask your local dealer about other u n K ryak rod ts th tor l rt d A e designed for riders by rides ra2. the OEM hardware If necessary tweak the bracket upward slightly so it does not contact the engine case STEP 13 Hold the Pro series hypercharger and support bracket assembly up to the bike e Slip the rubber intake duct with the OEM clamp onto the carburetor e Loosely fasten at the top two legs of the Y bracket to the Z and L brackets Use the supplied M6 X 1 0 X 16mm Socket Head Cap Screws and the supplied Tapered Bolt Caps as seen in PIC 8 PAGE 3 cont PRO SERIES HYPERCHARGER FOR ROAD STAR INSTALLATION kKurvakyn e Loosely fasten the lower leg of the Y bracket and idle speed adjuster bracket using the supplied Tapered Bolt Cap and the M6 serrated nut with the OEM fastener See PIC 9 It may be necessary to slightly adjust the position of the Z and L brackets in order to line up all mounting points STEP 14 Once all fasteners are in place fully tighten the lower leg of the main mounting bracket the two fasteners that hold the Z and L brackets to the cylinder heads and the two fasteners that hold the main mounting bracket to the Z and L brackets Tighten the OEM clamp securing the rubber intake duct to the carburetor NOTE To tighten the L bracket to the front cylinder head it may be necessary to momentarily remove the main mounting bracket from the L bracket to allow access to the M6 x 1 0 x 30mm socket head cap screw securing the L bracket to the head STEP 15 Connect all hoses You
3. ND COBRA LO BOYS STAGGERED DUALS Main Jet 182 5 Needle 1158j 72W clip in 2nd groove Pilot Air Bleed 1 3 Pilot Jet 37 5 ROAD STAR 1600 These items are in a separate small poly bag inside the jet kit Main Jet 205 Needle Add one 020 shim to raise needle Pilot Air Bleed 1 5 PAGE PRO SERIES HYPERCHARGER FOR ROAD STAR INSTALLATION
4. cke 401025 1 Idle Adjuster Bracket 2003 Ktiryakyn USA All Rights reserved 401042 1 Lower Mounting Bracket 909820 1 Jet Kit Containing the Following Ten Items 200027 1 020 Shim 400602 1 205 Main Jet 401351 1 1 5 Air Bleed 400889 1 175 Main Jet 401713 1 182 5 Main Jet 401693 1 185 Main Jet 401712 1 187 5 Main Jet 401711 1 1 3 Air Bleed 401710 1 37 5 Pilot Jet 401697 1 1158j 72W Jet Needle with Clips 309420 1 Installation Instruction THANK YOU FOR CHOOSING KURYAKYN 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 If you choose to attempt this procedure yourself refer to the carburetor removal disassembly reassembly and installation procedures outlined in your Road Star service manual cont 9421 21HD 1004 kuryakyn com The jets included in this kit were selected based on test results with various combinations of lt m components that we felt would represent the majority of the customers purchasing this kit see Kuryakyn Addendum I However no two motorcycles are exactly alike Depending on the individual case additional jets may need to be purchased from an outside source K ryakyn PIC 1 warrants t
5. f the motorcycle These baselines were established at 700 feet above sea level SETTING THE PILOT MIXTURE SCREW While the carburetor is removed for re jetting remove the pressed in plug covering the pilot mixture screw and as a starting point set the PMS two turns out from lightly bottomed Once the bike is completely reassembled start it and allow the engine to reach normal operating temperature The engine should idle on its own without the enrichener Search for the highest idle speed by slowly turning the PMS inward and outward there will be a small range where idle speed is maximized Once the highest idle speed has been located turn the PMS inward ever so slowly until the idle begins to drop then back it out just enough to make the idle speed pick back up You have now located the ideal PMS setting PAGE 4 cont PRO SERIES HYPERCHARGER FOR ROAD STAR INSTALLATION ROAD STAR 1700 WITH PRO SERIES HYPERCHARGER AND STOCK EXHAUST oni ne kurvakyn Needle 1158j 72W clip in 4th groove Pilot Air Bleed 1 3 Pilot Jet 375 ROAD STAR 1700 WITH PRO SERIES HYPERCHARGER AND COBRA SLIP ON MUFFLERS Main Jet 175 Needle 1158j 72W clip in 3rd groove Pilot Air Bleed 1 3 Pilot Jet 37 5 ROAD STAR 1700 WITH PRO SERIES HYPERCHARGER AND HARD KHROME STAGGERED STRAIGHTS Main Jet 182 5 Needle 1158j 72W clip in 2nd groove Pilot Air Bleed 13 Pilot Jet 37 5 ROAD STAR 1700 WITH PRO SERIES HYPERCHARGER A
6. he 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 NOTE Please read each step of the instruction before proceeding with the installation TOOLS SUGGESTED Standard and Metric hex keys 7 16 wrench 12mm wrench 10mm wrench 10mm socket and ratchet 1 Phillips screwdriver knife or scissors and a factory service manual for exact year and model in question ber Nipple Ru PROCEDURE STEP 1 Remove the seat fuel tank and OEM air cleaner assembly Disconnect the hoses connected to the air cleaner while leaving them connected to the motorcycle Save the clamp that secures the air duct to the carburetor and the OEM fasteners used to secure the stock air cleaner assembly to the motorcycle as some will be reused E Rubber Duct Installed in Pro series Hypercharger Back Plate STEP 2 Remove the carburetor according to the section in your Road Star factory service manual that outlines procedures for carburetor removal disassembly reassembly and installation Now is a good time to proceed with re jetting the carburetor We have supplied jets to cover many common configurations For jet locations and jetting recommendations with various exhaust combinations see Addendum I Since the OEM screws retaining the float bowl are easily damaged we have included replacement M4 socket head cap sc
7. may need to refer to the Yamaha Road Star factory service manual e The 3 8 I D hose is your crankcase breather hose Insert one end of the 3 8 barbed connector into this hose and then plug it into the large rubber nipple on the bottom of the rubber intake duct e Connect the float bowl vent hose from the carburetor to the plastic 90 degree fitting you installed in STEP 8 e Route the vacuum line connected to the T fitting installed in STEP 9 to the vacuum nipple located at the bottom of the vacuum pod on the back of the Pro series hypercharger STEP 16 Reinstall fuel tank and seat STEP 17 Start it up The butterflies should be completely open when the bike is not running closed and fluttering when the bike is idling and will open momentarily then close again if the throttle is blipped with the bike in neutral ADDENDUM I 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 However no two motorcycles are exactly alike Depending on the individual case additional jets may need to be purchased from an outside source The following recommendations are intended as a Starting point and should work well in the majority of cases Individual bikes may need additional tuning to achieve maximum performance If the exact combination is not listed choose the listing that most closely resembles the configuration o
8. rews to replace them if necessary STEP 3 Insert the rubber intake duct into the main support bracket as shown in PIC 1 The rubber nipple should be pointing toward the longest leg of the bracket STEP 4 Remove the 6 32 x 3 8 socket head cap screws securing the upper and lower butterfly shaft caps to the front half of the Pro series hypercharger case and the three 1 4 20 x 1 5 8 fasteners securing the front half to the back half of the air cleaner Remove the front half and filter element STEP 5 Insert the rubber intake duct into the Pro Series Pro series hypercharger in the same fashion it was installed in the main support bracket See PIC 2 You may need to use a screwdriver to help poke the flange of the Rubber Intake Boot into position inside the Pro series hypercharger STEP 6 Line up the three holes in the back plate of the Pro series hypercharger and the three holes in the flange of the rubber intake duct with the three holes in the main support bracket Insert the three supplied 1 4 20 X 5 8 socket head cap screws from inside the Pro series hypercharger and secure on the back side of the main support bracket with the 1 4 20 thin nylock nuts You will need to pull back the inner flange of the rubber intake duct to access PAGE 2 the holes Hold the nylock nuts with a 7 16 wrench as you tighten the socket head cap screws with a 3 16 hex key Be careful not to over tighten and cause the rubber intake duct to pucker around
9. the nylock nuts See PIC 3 PRO SERIES HYPERCHARGER FOR ROAD STAR INSTALLATION cont STEP 7 Reinstall the filter element and the front half of the air cleaner kurvakyn STEP 8 Install the supplied 90 degree barbed fitting into on the back side of the Pro series hypercharger The hole is located on the rearward tapered end of the air cleaner PIC 4 Thread the fitting in until the hex portion of the fitting is about 1 8 from contacting a moe the surface Vaun hose STEP 9 Tap into the vacuum source by cutting the vacuum line shown in PIC 4 This line comes from the top of the intake manifold near the rear cylinder head on the left side of the bike Install the supplied T fitting as shown in PIC 5 Connect the supplied 16 length of 5 32 vacuum line to the 3rd leg of the T fitting This section of line will be routed to the Pro series hypercharger in a later step STEP 10 Place the OEM clamp removed in STEP 1 on the end of the rubber intake duct in the same manner it was installed on the OEM air duct STEP 11 Loosely install the Z Bracket to the rear cylinder head and the L bracket to the front cylinder head using the supplied M6 X 1 0 X 30mm socket head cap screws See PIC 6 Their position may need to be adjusted slightly when the air cleaner is installed so do not tighten them fully at this time STEP 12 Install the chrome lower support bracket as shown in PIC 7 using
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