Installation Instructions
Contents
1. a walt A Carefully drain all gas from the carburetor B See FIG 1 Set the carburetor on its top with the float bowl facing upwards Observe the cylindrical casting to the rear of the float bowl Notice the brass plug in the end of that casting Use a center punch to make a divot in the end of this plug Using the supplied drill bit carefully drill out the center of the plug IMPORTANT Located below the plug is a brass adjustment screw Be extremely careful not to allow the drill bit to break through the plug and damage the screw below Start the supplied slotted pan screw into the hole you drilled and thread it in just enough for the threads to bite Grasp the screw with pliers and gently wiggle the screw back and fourth while pulling outward to remove the plug Turn the adjustment screw all the way in until it lightly bottoms out Back the adjustment screw out 3 1 2 turns from bottomed C Carefully remove the float bowl The stock 48 low speed jet is located in the deep cylindrical recess Remove and replace the main jet with one of the following 160 Used in high elevations and or with stock or restrictive exhaust 165 Used with baffled drag pipes like the Vance amp Hines Straight Shots 170 Muffled performance pipes like Cobra or Vance amp Hines Duals 180 Open drag pipes D Replace the float bowl E Carefully remove the carburetor top slide spring and slide The rubber diaphragm is very fragile Use caution2. PIC 2 STEP 7 Remove the hoses shown in PIC 3 from the rear of the stock air cleaner Insert the amp vinyl cap onto the end of the largest hose fresh air induction STEP 8 Remove the stock air cleaner support bracket Set it and its fasteners aside as they will be reused See PIC 4 STEP 9 Using a hex wrench loosen the clamp that secures the carb spigot to the intake f rs Waa INSERT CAP IN Sz fe STEP 10 See PIC 5 Remove the vacuum line float bowl vent fuel line throttle control cables and enrichener control from the carburetor PAGE cont 2 HYPERCHARGER INSTALLATION STEP 11 Pull the carb free of the manifold and remove it from the motorcycle Install the Jet Kit provided ms al G NOTE Now is a good time to proceed with re jetting of the carburetors Consult your factory service manual for this procedure We have supplied jets to cover most common applications 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 W k a baffled exhaust pipes We highly recommend NOT using drag pipes open style Using drag pipes in conjunction with our air cleaner may require Bp gene ene ieee additional jetting above and beyond the components included in this kit
3. INSTALLATION HYPERCHARGER AIR CLEANER 9410 PARTS INCLUDED 1 Hypercharger Chrome with Drilled Back 1 K amp N Filter Element 1 Mounting Kit Containing 1 Carburetor Adapter 1 Carburetor Support Bracket 1 Breather Adapter for Vulcan 800 1 Gasket Late Style with Adhesive 2 Gasket Late Style 3 1 4 20 x 2 Socket Head Cap Screws 1 1 4 20 x 5 8 Socket Head Cap Screw 2 M6 1 0 x 16mm Hex Head Cap Screws 4 1 4 Flat Washer Chrome 1 16 Length 5 32 Vacuum Hose 1 6 Length 3 8 Hose 1 Mini Three Way Tee 1 1 8 NPT Nipple 1 3 8 Connector Barbed 1 Cap 562 ID X 69 OD X 1 2 1 Male 1 8 27 Threaded 90 Elbow 3 Hose Clamps Stainless Jet Kit for VN800 Including 1 Fuel Injection Needle 2 E Clip for Fuel Needle 3 020 Needle Shim 1 5 32 Drill Bit 1 12 X 3 4 Slotted Pan Screw 1 160 Main Jet 1 165 Main Jet 1 170 Main Jet 1 180 Main Jet 1 Installation Instructions Please read and understand entire instructions before starting installation THANK YOU FOR CHOOSING KURYAKYN IN ORDER TO PROTECT YOU AND OTHERS FROM POSSIBLE INJURY AND OR PROPERTY DAMAGE OR LOSS PLEASE PAY CLOSE ATTENTION TO ALL INSTRUCTIONS WARNINGS CAUTIONS AND ATTENTION NOTES REGARDING THE USE AND CARE OF THIS PRODUCT WARNING THIS INDICATION ALERTS YOU TO THE FACT THAT IGNORING THE CONTENTS DESCRIBED HEREIN CAN RESULT IN POTENTIAL DEATH OR SERIOUS INJURY ATTENTION This indication a
4. ange the condition HYPERCHARGER INSTALLATION cont e From idle to 1 8 throttle is controlled by the idle mixture screw e 1 4 throttle to 3 4 throttle is controlled by the needle and needle jet e Just off idle to 1 4 throttle is controlled by the low speed jet Kuryakyn e 3 4 throttle to wide open is controlled by the main jet p NO T STEP 12 STEP 13 STEP 14 STEP 15 STEP 16 STEP 17 STEP 18 STEP 19 STEP 20 STEP 21 STEP 22 ATTENTION BARBED CONNECTOR Reinstall the carb on the manifold and re connect all hoses cables etc Tighten ANE 2o des the intake manifold clamp L j l Reinstall the stock carb support bracket Install the billet aluminum carburetor adapter on the mouth of the carburetor The adapter s slot should be in the 3 o clock position with the pinch bolt installed from the top Do not tighten the pinch bolt at this time Install the peel and stick gasket to the exposed surface of the adapter Install the chrome carb support bracket using the M6 1 0 x 15mm hex head cap ies screws provided PIC 6 If there is a gap between the stock air cleaner mounting bracket and the new carb support shim with the supplied 1 4 flat washers In eeu eae some cases it may be necessary to slightly bend the stock bracket so the carb BACK OF HYPER support will lay flat against the adapter when the M6 screws are tightened oer Install the 1 8 NPT x 3 8 O D nipple in the threa
5. ded hole in the bottom of the breather adapter Remove the trap door from the front with a 1 8 hex key remove the trap door on the front of the Hypercharger Install the Hypercharger and breather adapter as one unit The three 1 4 20 x 2 socket head cap screws will go through the back of the Hypercharger the breather adapter and the carb support then thread into the carb adapter Be sure to install gaskets between the Hypercharger and 2 D Oe breather adapter and the breather adapter and support bracket The breather See ee p nipple should point downward Note that one of the four holes in the Hypercharger 7 om 1 will not be used it is a vent hole for H D applications See PIC 7 In PIC 7 we have removed the front of the Hypercharger and the filter for clarity You need only remove the trap door Adjust the Hypercharger so it is horizontal before tightening the 1 4 20 x 2 screws Reinstall the trap door and securely tighten VE the adapter pinch bolt Insert the 3 8 barbed connector into the breather hose PIC 3 and add the 6 length of 3 8 I D hose included in the kit Plug the extended breather hose onto the breather adapter s nipple Secure all connections with the hose clamps provided PIC 8 VERY IMPORTANT Install the plastic 90 elbow in the threaded hole on the back of the Hypercharger The stock float bowl vent hose is routed from the carb back to a dead end location under the seat Pull this hose fr
6. ee from under the seat but leave it connected to the carb fitting Run this hose from the carb down to the 90 fitting on the back of the Hypercharger cut it to length and connect it to the fitting See PIC 9 See PIC 10 Locate the vacuum line going to the fuel petcock At a convenient location cut the line and install the T as shown Install the supplied length of vacuum hose to the T and connect the remaining end to the vacuum nipple on the bottom of the Hypercharger The butterflies will be wide open when the bike is off or at full throttle and mostly closed when the bike is at idle Re install the tank dash and seat in the same manner it was removed 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 4 HYPERCHARGER INSTALLATION
7. lerts 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 9410 23MC 1011 cont CUSTOMER SERVICE INSTALLATION QUESTIONS LIMITED WARRANTY ereunder sh TOOLS SUGGESTED o Set of Metric and Standard Hex Wrenches Set of Metric Combination Wrenches Phillips Screwdriver Kuryakyn STRICTLY OBSERVE THE FOLLOWING GUIDELINES IN ORDER TO USE THE PRODUCT 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 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 p
8. not to tear puncture or stretch it The needle can be addressed one of two ways 4U O TE O i 1 The stock needle works well when installed with the three supplied needle shims placed under the head of the needle raising the installed position of the needle NNS P 2 The supplied needle may also be installed providing further adjustment if additional performance modifications will be made F Once your choice of needle has been installed Replace the nylon needle retainer slide and slide spring G Carefully place the lip of the diaphragm into the groove in the top of the carburetor body and install the carburetor top IMPORTANT Be sure the diaphragm has not been pinched or damaged in any way during installation ANY leak in this seal will cause the bike to run poorly and will require replacement of the diaphragm i 1 i k h i TU CARBURETOR TUNING TIPS Several factors can influence the tuning and drivability of your motorcycle Altitude temperature and choice of exhaust will all affect performance Further adjustments may be required based on these factors Backfires through the intake generally indicate a lean condition Blubbering shuddering smoking and plug fowling indicate a rich condition If jet changes are required be certain that you change the jet causing the problem EXAMPLE If your bike exhibits a cough or backfire through the intake changing the main jet would not ch
9. urchased 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 ae ee PIC 1 ni ability to complete all of the steps in the procedure consult a trained EN g technician a i CAUTION The installation of any high performance exhaust system can cause a lean fuel air mixture A lean fuel air mixture can cause engine overheating resulting in severe engine damage K ryakyn recommends rejetting carbureted bikes STEP 2 Remove the seat from the motorcycle STEP 3 Remove the dash from the fuel tank You will have to unplug two plugs and unscrew the speedometer cable from the speedometer head STEP 4 Make sure the fuel petcock is closed Remove the fuel line and vacuum line from f the petcock and the vent hoses from the fuel tank Remove the fuel tank mounting bolts and remove the tank from the motorcycle STEP 5 Remove the air box from the bike See PIC 1 STEP 6 Remove the chrome air cleaner cover filter and backing plate from the bike See
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