Transcript
ALLEY CAT AIR CLEANER FOR STRYKER
9594
THIS INDICATION ALERTS YOU TO THE FACT THAT IGNORING THE CONTENTS DESCRIBED HEREIN CAN RESULT IN POTENTIAL DEATH OR SERIOUS INJURY. This indication alerts you to the fact that ignoring the contents described herein may negatively affect product performance and functionality or damage the product itself or the product to which it is being attached. ENSURE THAT THE FOLLOWING PARTS HAVE BEEN INCLUDED IN THE KIT: 1
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Alley Cat Cover Kit containing: 1 Alley Cat Cover containing: 1 Main Housing 1 Mesh 1 Hardware Kit containing: 1 Double Ended Stud 1 Nylon Ratchet 3 Foam Blocks 1 Tri Bar THIS PRODUCT IS NOT LEGAL FOR SALE OR Street Sleeper II Kit containing: USE ON POLLUTION CONTROLLED VEHICLES. 1 Backing Plate 1 Spider Weldment 1 Velocity Plate 1 Air Lock Ring 1 Hardware Kit containing: 5 8-32 X 3/8” Flat Socket Head Cap Screw 1 8-32 X 5/16” Button Socket Head Cap Screw 1 #8 Flat Washer 3 1/4”-20 X 3/4” Socket Head Cap Screw 3 1/4”-20 X 1/2” Socket Head Cap Screw 2 Vacuum Caps 1 Cap Retainer Filter Element Air Cleaner Adapter containing: 1 Adapter 1 Inlet Flow Plate Mount Kit containing: 1 Hardware Kit containing: 2 M5 X 0.8 X 14MM Socket Head Cap Screw 2 M5 Split Lock Washer 1 M6 X 1.0 X 50MM Socket Head Cap Screw 1 M5 Nylon Insert Lock Nut 1 Mount Weldment 1/2” Elbow Fitting Installation Instructions
YOU WILL ALSO NEED: Phillips head screwdriver, set of metric hex wrenches, set of metric sockets and ratchet, set of metric combination wrenches, model-specific service manual, IN LBS and FT LBS (NM) torque wrenches, Blue (242) Loctite or equivalent
9594-11MC-0715
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THE END USER’S SAFETY DEPENDS UPON PROPER INSTALLATION OF THIS PRODUCT. IF A STEP IN THESE INSTRUCTIONS IS NOT WITHIN YOUR CAPABILITIES OR YOU DO NOT HAVE THE CORRECT TOOLS, HAVE YOUR DEALER PERFORM THE PROCEDURE. IMPROPER INSTALLATION OF THIS PRODUCT COULD RESULT IN DEATH OR SERIOUS INJURY.
PIC 1
REMOVE THREE M5 SCREWS; SAVE FOR LATER
ACCIDENTAL VEHICLE START-UP COULD CAUSE DEATH OR SERIOUS INJURY, REMOVE THE MAIN FUSE BEFORE PROCEEDING. These installation instructions contain important information. Ensure that the end user receives this copy and is aware of its importance for future use.
STEP 1
STEP 2
Read and understand all steps in the instructions before starting the installation. Park the motorcycle on a hard, level surface and turn IGN OFF. Allow the engine and exhaust system to cool. Remove the main fuse.
Remove existing air cleaner cover and filter element; set it all aside, it will not be reused.
REMOVE NUT; NOT REUSED
REMOVE TWO SCREWS AND BRACKET; SAVE THE LONGER ONE FOR LATER
PIC 2
DISCONNECT THE HOSE FROM BACK SIDE OF THE BACKING PLATE
STEP 3
Refer to PIC 1. Remove the three M5 screws and nut as shown; save the screws for later use.
STEP 4
Refer to PIC 2. Disconnect the breather hose from the backside of the backing plate. Ensure the spring clip remains on the hose; it will be reused. Set the backing plate aside, it will not be reused.
PIC 3 STEP 5
Refer to PIC 1. Remove the bracket from the engine case; save the longer of the two screws for later use.
STEP 6
Refer to PIC 3. Remove the front Phillips head screw from the underside of the throttle body. Set the screw aside; it will not be reused.
BREATHER HOSE THROTTLE BODY
REMOVE THE FRONT SCREW
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STEP 7
NOTE:
Refer to PIC 4. Locate the included Mount Weldment. Secure the Mount Weldment to the underside of the throttle body with an included M5 X 0.8 X 14MM Socket Head Cap Screw and M5 Split Lock Washer. Leave the Screw finger tight for now.
PIC 4
Remove one Phillips head screw at a time to prevent dislodging the plate and Oring it secures.
STEP 8
Remove the rear screw from the underside of the throttle body. Pivot the Mount Weldment in until the holes align; secure the Weldment with the other M5 Screw and Lock Washer. Leave the Screw snug for now.
STEP 9
Refer to PIC 4. Follow the threadlocker manufacturer’s recommendations to prepare the threads of the M6 screws. Apply threadlocker to the threads of the screws. Secure the Weldment to the engine case with the included M6 Socket Head Cap Screw (front) and the existing screw (rear); leave them snug for now.
STEP 10
Refer to PIC 5. Thread the included 1/2” Elbow Hose Fitting into the included Air Cleaner Adapter. Ensure the Fitting points inward when installed. PIC 5
STEP 11
Refer to PIC 5. Install the included Rubber Inlet Flow Plate in the Adapter as shown.
STEP 12
Refer to PIC 6. Hold the Adapter assembly up to the throttle body; attach the breather hose to the Elbow Fitting and secure it with the hose clip.
STEP 13
Position the Adapter so that the Rubber Plate interlocks with the flange on the throttle body.
SECURE WITH TWO M5 SCREWS AND LOCK WASHERS
MOUNT WELDMENT
ALIGN HOLES AND SECURE WITH M6 SCREWS; TORQUE TO 7.2 FT LBS (10) NM INSTALL RUBBER INLET FLOW PLATE IN BACKSIDE OF ADAPTER. ENSURE PLATE FULLY SEATS IN RECESS
ELBOW FITTING POINTS INWARD
PIC 6 STEP 14
Refer to PIC 6. Secure the Adapter to the throttle body with the three OEM screws removed in STEP 3. Insert two of the OEM screws through the top two holes in the Adapter; begin threading them into the throttle body. Insert the third OEM screw through the bottom hole; secure it with the included Nylon Lock Nut. Leave the screws loose until all three have been started, then tighten.
STEP 15
Tighten the two M6 screws in the engine case; torque to 7.2 FT LBS (10) NM. Tighten the two M5 screws on the underside of the throttle body. DO NOT OVER TIGHTEN! Page 3
STEP 16
Refer to PIC 7. Locate the Backing Plate in the kit. install the included black rubber Vacuum Caps over the nipples on the Backing Plate. Attach the Cap Retainer with the supplied #8-32 Button Socket Cap Screw and #8 Flat Washer. Tighten securely. The dropped center of the Cap Retainer goes towards the Backing Plate.
PIC 7
VACUUM CAPS
CAP RETAINER
NOTE:
Some parts are shown being assembled off the bike for clarity; assemble parts on the bike by following the STEPS below.
AIR LOCK RING
BACKSIDE OF BACKING PLATE
STEP 17
Refer to PIC 8. Insert the three included 1/4-20 x 1/2” Socket Head Cap Screws through the mounting holes from the front of the Backing Plate.
PIC 8
Place the Air Lock Ring (shown in PIC 7) over the protruding ends of the screws from the back side. The Air Lock Ring will act as a gasket between the Backing Plate and the Air Filter Adapter, no extra gasket will be needed. Attach the Backing Plate assembly to the Air Filter Adapter with the three Screws; tighten them securely.
BACK PLATE INSTALLED
PIC 9 STEP 18
Locate the Velocity Plate in the kit. Position the Velocity Plate on the Backing Plate so that the slots align as shown in PIC 9. ALIGN SLOTS
STEP 19
Refer to PIC 10. Align the Spider Bracket with the slots in the Backing Plate and Velocity Plate. Attach it to the Backing Plate with the supplied #8-32 X 3/8” Flat Socket Cap Screws.
STEP 20
Locate the Air Filter Element in the kit. Refer to PIC 10. Rotate the Air Filter until it aligns with the Spider Bracket hex stud.
VELOCITY PLATE
PIC 10
PIC 11 STEP 21
Locate the included Double-Ended Stud in the kit. Insert the longer end of the Stud through the outside of the Alley Cat Cover as shown in PIC 11.
HEX STUD
SPIDER BRACKET
LONG END OF STUD
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STEP 22
Place a drop of blue thread locker on the longer end of the Double-Ended Stud. Place the Alley Cat Cover over the Filter and secure to the Spider Bracket with the Stud. Torque to 36-60 in/lbs. The Stud may need to be loosened a bit to line up the flats on the Stud with the dowels on the chrome Cover as shown in PIC 12.
STEP 23
Align the indents in the Nylon Ratchet with the dowels on the chrome Cover as shown in PIC 12.
STEP 24
STEP 25
Refer to PIC 13. Place a drop of blue thread locker on the exposed threads of the Stud; thread the Tri-Bar fastener onto the Stud. There are teeth on the Ratchet Ring that the teeth on the Tri-Bar will engage to help hold the it in place. The Tri-Bar only needs to be finger tight! DO NOT over tighten it!
PIC 12
LINE UP FLATS ON STUD WITH DOWELS ON COVER THEN NOTCHES ON RATCHET WILL LINE UP WITH DOWELS
PIC 13
Ensure 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.
If the OEM exhaust system is replaced or altered (in addition to replacing the air cleaner), then install Kuryakyn Wild Things Fuel Controller (P/N 9218 available at kuryakyn.com) to prevent a “lean” fuel/ air mixture that can result in over heating leading to engine damage.
It is the end user’s responsibility to ensure that all fasteners (including pre-assembled) are tightened before operation of the motorcycle. Kuryakyn will not provide warranty coverage on products or components lost or damaged due to improper installation or lack of maintenance. Periodic inspection and maintenance are required on all fasteners.
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