I N S Ta L L At I O N

Transcript

I N S TA L L AT I O N pro-r air cleaner 9465 f or k awasa k i Fits: A ll ‘ 0 4 & Up V ulcan 2000 models PartS Included 1 Pro-R Hypercharger Assembly, Less Filter 1 Hyper Filter, E-3506 Round 1 Mounting Kit for Pro-R, including: 1 Air Cleaner Manifold 1 V2K Manifold Insert 1 V2K Support Bracket 1 Rubber Base Mini Filter 1 Oxygen Sensor Mounting Bracket 1 20mm O-Ring 1 Hardware Kit for Pro-R, including: 1 Nipple, 1/8” Chrome 1 Elbow, 90 Degree, 1/4” Chrome 1 V2K O2 Sensor Retainer, Chrome 2 M6 Aluminum Tapered Bolt Cap 1 Spacer, 0.25 x 0.75 x 0.69” 1 Spacer, 0.25 x 0.75 x 1.44” 1 1/2” Wire Clamp 1 3/4” Wire Clamp 1 Gasket and O-ring Set 1 Fastener Kit for Pro-R V2K 4 M6 x 1 x 20 SHCS Fastener 2 M6 x 1 x 35 SHCS Fastener 1 M6 x 1 x 50 SHCS Fastener 1 10-24 x 5/8” BSCS Fastener 1 #5 Later Hyper Kit, including: 1 Hose, Black Rubber, 5/32 x 16” 1 Fitting, Black Nylon 2 Gasket, Late Style C-V w/o PSA 1 Gasket, Late Style w/adhesive 3 1/4-20 x 5/8” SHCS Fastener w/patch 1 Instructions for K&N Filter 1 Instructions for Pro-R Hypercharger Please read and understand entire instructions before starting installation. Thank you for choosing Küryakyn! 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. ATTENTION! This indication alerts you to the fact that ignoring the contents described herein may negatively affect product performance and functionality. Tools Suggested -cont.- Allen wrenches, combination wrenches, pliers, diagonal cutting pliers. 9465-13HD-1008 CUSTOMER SERVICE 877.370.3604 (toll free) INSTALLATION QUESTIONS [email protected] or call 715.247.2983 LIMITED WARRANTY Küryakyn warrants that any Küryakyn products sold hereunder, shall be free of defects in materials and workmanship for a period of one (1) year from the date of purchase by the consumer excepting the following provisions: • Küryakyn shall have no obligation in the event the customer is unable to provide a receipt showing the date the customer purchased the product(s). • The product must be properly installed, maintained and operated under normal conditions. • Küryakyn makes no warranty, expressed or implied, with respect to any gold plated products. • Küryakyn shall not be liable for any consequential and incidental damages, including labor and paint, resulting from failure of a Küryakyn product, failure to deliver, delay in delivery, delivery in nonconforming condition, or for any breech of contract or duty between Küryakyn and a customer. • Küryakyn products are often intended for use in specific applications. Küryakyn makes no warranty if a Küryakyn product is used in applications other than intended. • Küryakyn electrical products are warranted for one (1) year from the date of purchase by the consumer. Components of Küryakyn products containing L.E.D.s will be warranted for defects in materials and workmanship for 3 years from the date of purchase. • Küryakyn makes no warranty of any kind in regard to other manufacturer’s products distributed by Küryakyn. Küryakyn will pass on all warranties made by the manufacturer and where possible, will expedite the claim on behalf of the customer, but ultimately, responsibility for disposition of the warranty claim lies with the manufacturer. ABOUT OUR CATALOG Strictly observe the following guidelines in order to use the product properly and avoid potentially dangerous accidents. ATTENTION! It is the installer’s responsibility to ensure that all of the fasteners (including pre-assembled) are tightened before operation of the motorcycle. Küryakyn will not warranty components lost due to improper installation. Periodic maintenance may be required. PIC. 1 Notes ~The addition of this air cleaner may change the fuel requirements of the engine. For best drivability and performance we recommend the use of a “Wild Things Fuel Injection Controller”. Küryakyn P/N 9218. (Sold separately.) ~The following photos show the fuel tank removed. You do not need to remove the fuel tank; loosening the rear fastener and propping up the end of the tank should give you enough clearance to complete the procedure. ~Some of our high performance air cleaners extend beyond the stock/OEM unit to achieve smoother air flow and better performance. Riding position may be affected. 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 steps in the procedure; consult a trained technician. PIC. 2 Procedure STEP 1 Park the motorcycle on a hard, level surface. Shut off the ignition and allow the engine to cool. STEP 2 Remove the seats and securely prop up the rear end of the gas tank; refer to stoc k air f ilter your service manual. STEP 3 Loosen the fasteners and remove the cover on the stock air cleaner cover. See PIC. 1. PIC. 3 STEP 4 Remove the air filter. See PIC. 2. STEP 5 Loosen the fasteners and remove the stock air cleaner backing plate. See PIC. 3. STEP 6 Disconnect the oxygen sensor (PIC. 4) and the crankcase breather hose (PIC. 5). STEP 7 Assemble the air cleaner manifold. Place the manifold insert into the stoc k air cleaner back ing plate air cleaner manifold; ensure that the cut out for the bolt aligns with the hole in the manifold. See PIC. 6. PIC. 4 -cont.PIC. 5 PIC. 6 oxygen sensor ensure t h at th e “cut-out ” aligns wit h th e h ole in t he mani fold remove crankcase breat her h ose ensure t h e “ hollowed - out” side is positioned as s h own . manifold insert Page 2 pro - r air cleaner INSTALLATION STEP 8 Insert the manifold o-ring into the groove on the back-side of the manifold. See PIC. 7. STEP 9 Insert the oxygen sensor. See PIC. 7. Note: For '08 & Up models with the smaller PIC. 7 sensor, use the adapter mounting bracket. STEP 10 Attach the oxygen sensor retainer with the 10-24 fastener. Ensure that the connector tab is facing away from the retainer. See PIC. 7. Set manifold assembly aside. STEP 11 Hold a throttle body gasket against the throttle body, ensuring that the middle hole is on the top. See PIC. 8. STEP 8 Insert O-ring STEP 9 insert ox ygen sensor STEP 12 Secure the gasket against the throttle body with the support bracket and the other throttle body gasket. Refer to FIG. 1. connector tab facing away f rom retainer STEP 13 Fasten the manifold assembly to the throttle body using the four (4) M6 x 1 x 20 and one (1) M6 x 1 x 35 fasteners. See PIC.9. Finger tighten at this time. STEP 14 Install a 35mm bolt through a tapered step 10 inster oxygen sensor retainer bolt cap, through the FRONT hole in the support bracket; slip the SHORT stand-off between the support bracket and the threaded hole in the FRONT cylinder. Finger tighten the bolt. See FIG. 1. STEP 15 Install a 50mm bolt through a tapered step 1 0 secure with 1 0 - 2 4 screw PIC. 8 bolt cap, through the REAR hole in the support bracket; slip the LONG stand-off between the support bracket and the threaded hole in the REAR cylinder. Fully tighten both the front and rear support bolts and the manifolds bolts. See FIG.1. STEP 16 Install the 90 degree elbow fitting into the threaded hole in the manifold; teflon paste or equivalent is recommended on the tapered threads. ensure t h e middle h ole is on th e top STEP 17 Install the 1/8” nipple after the elbow fitting is positioned angling inboard to reduce hose kinks. Use of a teflon paste or equivalent is recommended. FIG. 1 9 0 degree elbow f itting 1 / 8” nipple PIC. 9 t h rottle body gas kets mini f ilter mani fold insert long in rear s hort in front air cleaner mani f old -cont.- tapered bolt caps support brac k et Page 3 pro - r air cleaner INSTALLATION NOTE: The crankcase breather hose, removed in STEP 6, will need to be re-routed above the rear cylinder and angled downward toward the manifold. See PIC. 10. STEP 18 Place 1/2” clamp onto crankcase breather hose; push the crankcase breather PIC. 10 hose over the nipple from STEP 17 and secure with clamp. STEP 19 Remove the fresh air intake hose from the air cut valve, place the 3/4” clamp onto the mini-filter; install the mini-filter inline and secure with the clamp. See PIC. 11. STEP 20 Remove rear vacuum plug on the throttle body and attach the 16” vacuum hose to the nipple. See PIC. 11 and PIC. 12. STEP 21 Remove the three 1/4-20 bolts from the Pro-R assembly; set aside for later use. STEP 22 Remove the top and bottom outside 6-32 screws from the “R” end caps; set aside for later use. Remove the outside Pro-R cover from backing plate. PIC. STEP 23 Hold the manifold gasket against the manifold with the Pro-R air cut valve Hypercharger backing plate; fasten with the three (3) 1/4-20 x 5/8” bolts. See PIC. 13. STEP 24 Install the velocity ring. Ensure that the ring is fully pressed in. See PIC. 14. STEP 25 Install the air filter; ensure that the air filter seats around the locating ring. See PIC. 15. Remove f resh air intake h ose f rom air cut valve and replace with t he mini-filter; secure with t he 3/4” clamp. STEP 26 Install flat end filter on circular filter; ensure that it is fully pressed into place. PIC. 12 STEP 27 Place the Pro-R outer cover over the filter; ensure that the filter remove rear vacuum plug edges are inside the locating ring of the outer cover; loosely secure outer cover with the three fasteners previously removed in disassembly. STEP 28 Install the two 6-32 x 3/8” screws in the “R” end caps as shown in PIC. 16. STEP 29 Tighten all remaining fasteners. STEP 30 Push vacuum hose onto the “pod” nipple shown in PIC. 17. STEP 31 Reinstall the tank bolt and seats. PIC. 13 STEP 32 Test for proper operation and clearance. Note: The installation of any high performance air cleaner and/or exhaust system can cause a “lean” fuel/air mixture. A “lean” fuel/air mixture can cause engine overheating resulting in severe engine damage. It is highly recommended to install a programmable fuel injection module, such as Küryakyn P/N PIC. 14 9218, to regulate the fuel/air mixture. 1/4 - 2 0 bolts secure t he pro- r and gask et to manif old Page velocity ring -cont.- 4 pro - r air cleaner INSTALLATION PIC. 15 air filter seats around locating ring PIC.16 PIC. 17 attach vacuum hose to “pod” nipple Page 5 pro - r air cleaner INSTALLATION