Kuryakyn 9400 HYPERCHARGER AIR CLEANER KIT - Manual (Page 2)

PAGE
2
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 for this Motorcycle.
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 purchased from an outside
source. Küryakyn 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 overheating
resulting in severe engine damage. Küryakyn 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:
• 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.
• 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!!
• 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.
HYPERCHARGER
INSTALLATION
-cont.-