I N S TA L L AT I O N

HYPERCHARGER AIR CLEANER
F I T S : - U P K AWA S A K I V N 0 V U L C A N

E-MAIL

PA R T #

309410

INCLUDED
1 Hypercharger Chrome with drilled back Jet Kit for VN800 Mounting Kit containing the following: Carburetor Adapter Carburetor Support Bracket Breather Adapter for Vulcan 800 Gasket, Late Style with Adhesive Gasket, Late Style 1/420 x 2 SHCS with Blue Patch 1/420 x 5/8 SHCS Stainless M61.0 x 16mm HHCS Stainless 1/4 Flat Washer Chrome 5/32 Vacuum Hose, 16 Length Mini Three-Way Tee 1/8 NPT Nipple 3/8 Hose, 6 Length 3/8 Connector, Barbed.562 I.D. x.690 O.D. x 1/2 Long Vinyl Cap Male 1/827 Threaded 90 Elbow Hose Clamps Stainless Instruction Sheet
techsupport@kuryakyn.com or call 715.247.2983

WA R R A N T Y

Kryakyn warrants that any Kryakyn product sold hereunder, if properly installed, maintained and operated under normal conditions, shall be free from any defects in materials and workmanship for a period of one (1) year from the date the Kryakyn products are sold to the customer. CONSEQUENTIAL DAMAGES: Kryakyn shall not be liable for any consequential or incidental damages.
A B O U T O U R C ATA LO G
Youll find all our innovations for H-D, GL and Metric Cruisers in our annual catalogs. Order online todayselect the CATALOGS icon. Each Kryakyn product comes with a Proof-of-Purchase good for a complimentary catalog. Details in packaging. Be sure to ask your local dealer about other Kryakyn products, the motorcycle parts and accessories designed for riders by riders. 2003 Kryakyn USA All Rights reserved.
Replacement components for Hyperchargers are readily available. See our full line catalog or web site (www.kuryakyn.com) for part numbers and pricing.

TOOLS SUGGESTED

Metric combination wrenches, Metric sockets with ratchet, Phillips and slotted screwdrivers, Small pliers, Metric and fractional hex key wrenches, and a Cutter or knife.
Warning Gasoline is extremely flammable. To reduce the possibility of harmful or fatal fire from accidental ignition of fuel from the tank, we suggest disconnecting the battery cables from the battery before beginning this install. Use good judgment and do not smoke.

PROCEDURE

AVERAGE TIME: 23 HOURS STEP 1 Remove the seat from the motorcycle.
STEP 2 Remove the dash from the fuel tank. You will have to unplug two plugs, and unscrew the speedometer cable from the speedo head. STEP 3 Make sure the fuel petcock is closed. Remove the fuel line and vacuum line from the petcock and the vent hoses from the fuel tank. Remove the fuel tank mounting bolts and remove the tank from the motorcycle. -cont.9410-21HD-1103

Illiana

STEP 4 Remove the airbox from the bike. See PIC.1. STEP 5 Remove the chrome air cleaner cover, filter, and backing plate from the bike. See PIC.2. STEP 6 Remove the hoses shown in PIC.3 from the rear of the stock air cleaner. Insert the vinyl cap onto the end of the largest hose (fresh air induction). STEP 7 Remove the stock air cleaner support bracket. Set it and its fasteners aside as they will be reused. See PIC.4. STEP 8 Using a 3mm Allen wrench, loosen the clamp that secures the carb spigot to the intake manifold. STEP 9 See PIC.5. Remove the vacuum line, float bowl vent, fuel line, throttle control cables, and enrichener control from the carburetor.
PIC.3 PIC.4 PIC.2 P I C.1
STEP 10 Pull the carb free of the manifold and remove it from the motorcycle. Install the Jet Kit provided, P/N 8562, following its detailed instructions.
STEP 11 Reinstall the carb on the manifold, and re-connect all hoses, cables etc. Tighten the intake manifold clamp. STEP 12 Reinstall the stock carb support bracket. STEP 13 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.
STEP 14 Install the chrome carb support bracket using the M6-1.0 x 15mm hex head cap 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 some cases it may be necessary to slightly bend the stock bracket so the carb support will lay flat against the adapter when the M6 screws are tightened. STEP 15 Install the 1/8" NPT x 3/8" O.D. nipple in the threaded hole in the bottom of the breather adapter. -cont.-

PA G E

STEP 16 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 breather adapter and the breather adapter and support bracket. The breather nipple should point downward. Note that one of the four holes in the Hypercharger 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 the adapter pinch bolt. STEP 17 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).

STEP 18 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 free 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. STEP 19 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 P I C.bike is at idle. STEP 20 Re-install the tank, dash, and seat in the same manner it was removed.

Ride On!