Kuryakyn 9405 HYPERCHARGER AIR CLEANER - Manual (Page 2)

PAGE
2
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.
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 air cleaner system can cause a “lean”
fuel/air mixture. A “lean” fuel/air mixture can cause engine overheating
resulting in severe engine damage. Küryakyn recommends installing our Wild
Things Controller, P/N 9218, on fuel injected bikes, or having the bike tuned
by an experienced tuner, on a dyno, with an exhaust gas analyzer.
ATTENTION! This kit requires the removal of the complete stock air cleaner/intake tract up to the
throttlebody, as well as the “cold start circuit” components. If you wish to keep these
parts for possible re-installation at a later date, the throttle body must be removed from
the engine to remove the crossover duct. If you are certain these parts will not be
reused, the flange ends of the crossover duct may be cut off using a hack saw blade.
This method will significantly shorten the installation process. If you choose to keep the
crossover duct in tact, you MUST refer to your shop manual as this is a complicated
process. You may wish to have this installation performed by a qualified Kawasaki
service technician if you are not completely confident in your ability to perform these
procedures.
STEP 2 Remove the seat
STEP 3
Disconnect the battery positive cable to prevent sparking that could cause
ignition of spilled fuel, and personal injury.
STEP 4
Remove the fuel tank.
IMPORTANT- Throughout this installation, we strongly recommend labeling all
hoses, and the nipples they were removed from.
STEP 5
Remove the intake ductwork, air inlet, right and left air cleaner housings, air
cleaner, cold start components (see PIC.1), air mass sensor, and support
bracketry. The wires that were unplugged from the cold start solenoids, may be
neatly bundled and tucked out of harms way and out of sight. Be sure the
terminals are insulated so they cannot short to any surrounding parts. Insert
plugs (3/8” x 1/2” socket head bolts work well) into the two hoses that
connected to the cold start circuit lines. (See PIC.2.) Also unplug the crankcase
breather hose from the right angle fitting at the bottom of this enclosure, and
the large diameter hose from the fresh air injection valve. (Don’t forget to
label.) The fuel drain hose will not be re-used. PIC.3 shows what you’ll have left
when all components are removed.
STEP 6
From the hardware kit, find the front and rear support tabs and the four
M6 x 1.0 x 16mm socket head cap screws. Install the support tabs to the
threaded holes in each cylinder, and to the holes in the throttle body as shown
in PIC.4.
STEP 7
From the hardware kit, find the M6 x 1.0 x 16mm hex bolt and lock tab washer. Also find the
intake gasket (oval shape with two large holes) and the manifold adapter body. See PIC.5. Screw
the air temperature sensor into the back of the manifold adapter body. Place the intake gasket
over the mouth of the throttle body so all holes line up. Insert the M6 hex bolt through the lock
tab washer, and secure the adapter body to the throttle body, again making certain all holes line
up perfectly. Tighten the hex bolt, but do not bend the lock tabs yet.
HYPERCHARGER
INSTALLATION
-cont.-
PIC 1
PIC 2
PLUG THESE TWO HOSES