Installation Instructions
Contents
1. B Carefully remove the diaphragm and slide from the carb C Remove the spring plastic retainer and needle from the slide D See FIG 1 Very carefully drill out the slide lift hole with the included 070 drill bit Be sure to remove all filings from drilling Place the small E Clip in the third groove from the top of the needle See FIG 2 Stack two 020 shims on top of the E Clip The shims will keep the needle from bouncing in the slide E Carefully replace the needle slide assembly into the carb body Place the stock plastic retainer over the end of the needle and shims The retainer should gently seat over the shims Place the spring over the retainer Carefully seat the lip of the diaphragm in the corresponding groove in the carb body DO NOT FOLD PINCH TEAR OR PUNCTURE THE DIAPHRAGM Replace the top cover F READ THIS ENTIRE STEP BEFORE PROCEEDING See FIG 3 Turn the carb upside down Using the supplied 5 32 drill bit slowly drill out the plug covering the idle mixture screw The mixture screw is made of brass If you drill to far you will destroy the slot in the adjustment screw making adjustment impossible Once the hole is drilled start the supplied slotted pan screw into the drilled hole just far enough for the threads to bite Grasp the head of the screw with a pliers and pull outward in a slight rocking motion until the plug comes free G Using a small flat head screwdriver slow and gently turn the adjustment2. Let cool 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 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 Kuryakyn warrants the 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 WARNING YOU WILL BE WORKING AROUND THE ENGINE AND EXHAUST SYSTEM DURING INSTALLATION ENSURE THAT THE ENGINE AND EXHAUST SYSTEM HAVE FULLY COOLED TO PREVENT INJURY ATTENTION A factory service manual may be helpful in performing this installation Do not attempt to perform this installation if you are not confident in your ability to complete all of the steps in the procedure consult a trained technician CAUTION The installation of any high performance exhaust system can cause a lean fuel air mixture A lean fuel air mixture can cause engine
3. ARGER INSTALLATION cont Kuryakyn STEP 10 Remove the brackets that held each round backing plate The right hand bracket is Pica also a carb stabilizer This function is duplicated with one of the included brackets Bic i A STEP 11 Remove the carburetor according to the section in your factory service manual that outlines procedures for carburetor removal disassembly reassembly and r LABELS BS e installation We recommend that you label each hose or fitting as they are re Ce Ki moved to make reassembly easier An example of hose labeling is shown in PIC 1 i Se N s A C gt x tia CARBURETOR RE JETTING PROCEDURE NOTE Different combinations of aftermarket exhaust and air cleaners will have a Significant impact on carburetor jetting The supplied jetting components have been tested and found to be a good combination to produce drivability and performance with stock or free flowing muffled baffled exhaust pipes We highly recommend NOT using drag pipes open style Using drag pipes in conjunction with our air cleaner will require additional jetting above and beyond the components included in this kit A Consult your factory service manual for details of this procedure We have supplied jets Slide to cover many common configurations Remove the four Phillips head screws securing i the plastic carb top to the carb body Carefully remove the plastic carb top making sure Lift Hole not to damage the rubber diaphragm
4. INSTALLATION PRO HYPERCHARGER AIR CLEANER 9404 PARTS INCLUDED 1 Pro Hypercharger with K amp N Filter 1 Adapter Hardware Kit Contains the Following Seventeen Items or call 715 247 2983 1 Rubber Intake Duct with Rubber Carb Bumper Main Support Bracket Po _LIMITED WARRANTY Carb Bumper Bracket TE ae oa E E Ge can A 18 Length of 5 32 Rubber Hose naterials and workmanship for a period o 3 way Barbed T Fitting T ene ee a eee 1 4 20 X 5 8 Socket Head Cap Screw i ems gee eree rey 1 4 20 Nylock Nut e K 1 4 20 X 1 2 Button Socket Cap Screw 1 4 Flat Washer Step Reducer Washer 90 Degree Elbow 6 Length of 3 8 Rubber Hose Hose Clamp ak rvakvn mak 3 8 Barbed Nylon Connector M6 X 1 0 X 16mm Hex Head Cap Screw PrO M6 Flat Washer eK ryakyn shall not be liable for any Gray Vinyl Cap consequential and incidental damages NC ANC et Kit Includes the Following Ten Items iin ond Tallies odene aai 5 32 Drill Bit elivery delivery in nonconforming condition o1 50 Drill Bit of Ree EARE OE A ee 132 Main Jet aia 135 Main Jet eK ryakyn 138 Main Jet 140 Main Jet Needle E Clip one 1 year from the date of purchase by tl 020 Needle Shim consumer L E D S contained in componen Slotted Pan Screw E E A 1 Installation Instructions Please read and understand entire instructions before starting installation THANK YOU FOR CHOOSING KURYAKYN nodules wiring chrome amp other component IN ORDER TO PROTECT
5. YOU AND OTHERS FROM POSSIBLE INJURY AND OR E wdnentpereny tik PROPERTY DAMAGE OR LOSS PLEASE PAY CLOSE ATTENTION TO ALL ___ regard to other manufacturer s products INSTRUCTIONS WARNINGS CAUTIONS AND ATTENTION NOTES REGARDING a ga i ee THE USE AND CARE OF THIS PRODUCT CUSTOMER SERVICE INSTALLATION QUESTIONS BPNFPRPRPRPRPRPRPRPYERPNNNAADRPRPNNNUWRPRP RP eB WARNING THIS INDICATION ALERTS YOU TO THE FACT THAT IGNORING with the manufacture THE CONTENTS DESCRIBED HEREIN CAN RESULT IN ABOUT OUR CATALOG POTENTIAL DEATH OR SERIOUS INJURY no ATTENTION This indication alerts you to the fact that ignoring the contents described herein may negatively affect product performance and functionality CAUTION This indication alerts you to the fact that ignoring the contents described herein can result in potential injury or material damage TOOLS SUGGESTED Set of Metric and Standard Hex Wrenches Set of Metric and Standard Combination Wrenches the Bike s Tool Kit Metric Socket Set Small Vice Grip Silicone Phillips Screw Driver Needle Nose Pliers Small Flat Tip Screwdriver Diagonal Cutter Drill and a Service Manual 9404 23MC 1011 cont STRICTLY OBSERVE THE FOLLOWING GUIDELINES IN ORDER TO USE THE PRODUCT Kuryakyn PROPERLY AND AVOID POTENTIALLY DANGEROUS ACCIDENTS STEP 1 Read and understand all steps in the instructions before starting the installation Park the motorcycle on a hard level surface and turn off the ignition
6. are experiencing backfiring through the exhaust check the following before you assume the carburetor is improperly jetted STEP 12 STEP 13 STEP 14 STEP 15 STEP 16 STEP 17 STEP 18 cont MAKE SURE BOTH FLANGES ARE THROUGH BRACKET A Leaking exhaust pipe gaskets FLANGED END OF RUBBER BUMPER ON THIS SIDE OF BRACKET B Leaking fresh air system block off plate gaskets if applicable C If the fresh air system was not removed be sure the plug has not come out of the 3 4 inlet hose Reinstall the carburetor according to the section in your factory service manual that outlines procedures for carburetor removal disassembly reassembly and installation Insert the supplied rubber intake duct through the main support bracket making sure both flanges are through the support bracket as shown in PIC 2 Install the 90 Degree Elbow into the threaded hole in the Hyper back plate located at the rear section pointed end Insert the flanged end of the rubber carb bumper through the opening in the center of the chrome carb bumper bracket You will need a small flat head screwdriver to push it through The knob should protrude through the bracket in the opposite direction as the two mounting tabs at each end of the bracket See PIC 3 Mount the bumper bracket to the carb support bracket as shown in PIC 4 using the 1 4 20 x 5 8 button head cap screws reducer washers 1 4 flat washers an
7. d Nylock nuts When positioned correctly the rubber carb bumper will be positioned directly between the two vertical parallel flanges on the carb body once the assembly is mounted to the engine Remove the three fasteners that secure the front cover of the Pro Hypercharger Also remove the two outer most socket head caps screws that secure the bearing caps on the top and bottom of the butterfly shaft Remove the front cover of the Pro Hypercharger Insert the rubber intake duct through the Hyper back plate in the same fashion it was installed in the main support bracket See PIC 5 You may need to use a screwdriver to help poke the flange of the Rubber Intake Boot into position inside the back plate PRO HYPERCHARGER INSTALLATION STEP 19 STEP 20 STEP 21 STEP 22 STEP 23 STEP 24 STEP 25 STEP 26 STEP 27 CAUTION STEP 28 STEP 29 STEP 30 STEP 31 ATTENTION eo See PIC 5 Roll back the inner lip of the rubber intake duct align the mounting holes in the Kuryakyn Hyper back plate rubber intake duct and support bracket and insert a supplied 1 4 20 x 5 8 Socket Head Cap Screw through each hole Secure on the bracket pic 6 Wi side of the assembly with the supplied 1 4 20 Nylock Nuts Tighten snugly Replace the front cover of the Pro Hypercharger in reverse manner as it was re moved in STEP 17 Remove the large hose clamp from the OEM rubber air cleaner boot air cleaner t
8. ed at the bottom of the vacuum pod on the inner front portion of the hyper back plate See PIC 7 The float bowl vent hose is connected to the left rear of the carb Remove this hose from the bike and cut four inches off of the end that was previously connected to the carburetor Reconnect the cut end of the hose to its original location Route the vent hose downward under the carb and connect it to the 90 Degree Elbow that was installed in the back plate of the hyper See STEP 14 If the float bowl vent hose is pinched or kinked your bike will not H run properly i A GRAY VINYL CAP See PIC 8 Insert the supplied Gray Vinyl Cap in to the fresh air inlet hose that was 2 l Eog ei connected to the crossover tube You may choose to spread a thin layer of silicone NS inside the hose to help secure the cap inside the hose Reinstall the air box Work backwards from STEP 8 to STEP 2 to complete the installation Double check the tightness of all related fasteners check for hose clearance and check throttle for correct operation making sure it returns properly before starting the bike It is the installer s responsibility to ensure that all of the fasteners including preassembled are tightened before operation of the motorcycle Kuryakyn will not warranty components lost due to improper installation Periodic maintenance may be required PAGE PRO HYPERCHARGER INSTALLATION
9. o carburetor connection and install it on the carb end of the new rubber intake duct Locate the vacuum line shown in PIC 6 located at the left front side of the carb Cut the vacuum line about three inches form the carb and insert the supplied T fitting as shown Connect one end of the supplied 18 hose to the remaining outlet on the T fitting and route the other end downward on the forward side of the carburetor This end will be connected in a later step ti A LX TO HYPERCHARGER We 5 N N f y i si kig binan Insert one of the supplied 3 8 double ended hose barbs into each end of the PIC 7 supplied section of 3 8 hose and secure them in place using the supplied hose clamps Insert one end of the hose and barb assembly into the breather port gt located at the bottom of the rubber intake duct and secure it using a supplied hose clamp Hold the Hypercharger assembly in position Slide the rubber intake duct over the hi mouth of the carb and secure the mounting bracket to the cylinders with the M6 g Hex Head bolts and flat washers provided Tighten the hose clamp around the Av P mouth of the carb i Route the loose end of the hose and barb assembly installed in STEP 23 to the crank case breather hose previously connected to the OEM right side air cleaner back plate and secure using the remaining hose clamp Connect the open end of the 1 4 hose installed in STEP 22 to the vacuum nipple locat
10. overheating resulting in severe engine damage Kuryakyn recommends rejetting carbureted bikes STEP 2 Remove the seat STEP 3 Remove the bottom of the three dash plaque bolts 8mm STEP 4 Lift up on the dash panel and unscrew the speedometer cable knurled nut STEP 5 Unplug the three electrical connections STEP 6 With a 12mm socket remove the tank mounting bolt under the dash and at the rear of the tank STEP 7 Close the fuel valve and clamp off the fuel line Disconnect the line from the fuel valve STEP 8 Raise the rear of the tank and disconnect the two vent hoses and remove the tank STEP 9 Refer to the section of your factory service manual that deals with removal and installation of the following components e Remove the two round chrome air cleaner covers their backing plates the stock black plastic air box air inlet under tank and the crossover tube e Remove the intake manifold to remove and crossover tube Use extreme care when replacing the intake manifold Uneven torque damage to the intake gaskets or contamination can cause an intake leak that will result in very poor running and nearly impossible jetting e Unplug all hoses or lines from these components You may want to label these hoses at this time The Largest of these hoses 3 4 I D is for the fresh air injection system the second largest 3 8 I D is the crankcase breather The smallest of the hoses is a drain PAGE 2 PRO HYPERCH
11. screw inward clock wise until it lightly bottoms out Once lightly bottomed out back the adjustment screw outward counter clock wise three full turns H Remove the four Phillips head screws that secure the float bowl to the carb body Remove the float bowl being extremely careful no to disturb the position of the float I Replace the stock low speed jet with the supplied 48 jet Replace the stock main jet with the supplied 135 jet PAGE 3 cont PRO HYPERCHARGER INSTALLATION CARBURETOR TUNING TIPS e Run the bike until it reaches operating temperature Adjust the idle mixture screw until the bike reaches it s highest idle speed Reset the idle speed with the idle adjustment V knob e If further tuning is required let your spark plugs be your guide A white or uncolored plug indicates a lean condition while a black or sooty plug indicates a rich condition e Be sure you re working with the correct jet The low speed pilot jet affects throttle positions of about 1 8 open to approximately 1 3 open The main jet affects throttle Kuryakyn positions of about 3 4 open to wide open Needle position affects most throttle settings in between In other words don t change the main jet if you are experiencing a lean condition just off idle e Generally speaking popping of backfiring through the carb indicates a lean condition Blubbering smoking or popping out the exhaust indicates a rich condition e If you
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