I just installed a Kuryakyn Pro Hypercharger on my bike. The instructions said to install the air temp sensor into the manifold bracket but it didn't say to hook it up. I have a FI light illuminated and get a backfire from the tailpipe. Other than that the bike runs fine. I also installed a Cobra FI2000 fuel processor. Thanks!
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INSTALLATION - UPPER INTAKE MANIFOLD 1)Clean and inspect gasket sealing surfaces. 2)Position new gasket. 3)Install the throttle body on the upper intake (if required). 4)Install upper intake manifold and hand start all attaching bolts. 5)Tighten bolts gradually starting in the center working outward until a torque of 12 Nm (105 inch lbs.) is obtained. 6)Install the front and rear intake manifold support brackets. 7)Install the oil level indicator and oil fill tube to intake manifold bolts (Fig. 155). 8)Install the EGR tube. 9)Connect vacuum lines to the following (Fig. 156): Positive Crankcase Ventilation (PCV) Valve EVAP Purge Solenoid Power Brake Booster 10)Install alternator support bracket (Fig. 156). 11)Connect electrical connectors to the following (Fig. 157): Manifold Tuning Valve (MTV) Exhaust Gas Recirculation (EGR) Throttle Position Sensor (TPS) Idle Air Control (IAC) Manifold Absolute Pressure (MAP) 12)Install the throttle and speed control cable bracket and retaining bolts. 13)Install throttle and speed control cables to bracket and throttle arm. 14)Install air cleaner housing and inlet hose. 15)Install the engine cover. 16)Connect negative battery cable.
Fig. 4: Exploded view of the EGR system and related components for the 4.0L engine (click over pic for zoom) REMOVAL & INSTALLATION
PFE/DPFE Sensor This component is found on all engines, and is also referred to as the backpressure transducer.
Disconnect the negative battery cable.
Detach and label the wiring harness connector from the PFE/DPFE sensor.
Disconnect all of the hoses from the sensor.
Remove the mounting nuts, then separate the sensor from the mounting bracket.
If necessary, remove the EVR solenoid and the PFE/DPFE mounting bracket from the upper intake manifold.
To install:
If removed, install the EVR solenoid and mounting bracket onto the upper intake manifold.
If applicable, install the EGR tube heat shield.
Position the PFE/DPFE sensor on the mounting bracket, then install and tighten the mounting nuts until snug.
Attach all necessary hoses and wiring to the sensor.
Connect the negative battery cable.
EGR Vacuum Regulator (EVR) Solenoid The EVR solenoid is mounted either on the same bracket as the
PFE/DPFE sensor, attached to the upper intake manifold, or near the EGR
valve on its own bracket.
Disconnect the negative battery cable.
Label and detach the wiring harness connector from the EVR solenoid.
Detach the main emission vacuum control connector from the solenoid.
Remove the retaining nuts, then separate the solenoid from the mounting bracket.
To install:
Position the solenoid on its mounting bracket and install the retaining nuts.
Attach the main emission vacuum control connector and the wiring harness connector to the EVR solenoid.
Connect the negative battery cable.
EGR Valve See Figures 6 and 7
Disconnect the negative battery cable.
If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
Label and detach all vacuum hoses from the EGR valve.
Label and detach any electrical wiring harness connectors from the EGR valve.
Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
Fig. 6: Cutaway view of a base entry type EGR valve
Fig. 7: Cutaway view of a side entry type EGR valve To install:
Install the EGR valve, along with a new gasket, on the upper
intake manifold, then install and tighten the mounting bolts to 4-22 ft.
lbs. (20-30 Nm) on 3.8L engines, or to 106-49 inch lbs. (1-18 Nm) on
5.0L engines.
Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
Connect all wiring or hoses to the EGR valve.
Install the air inlet tube.
Connect the negative battery cable.
Hope this helps, good luck (remember to rate this comments).
If the manifold was replaced, install or connect the following:
Vacuum source manifold.
Positive Crankcase Ventilation (PCV) valve.
Manifold Absolute Pressure (MAP) sensor.
Throttle body assembly.
Upper-to-lower intake manifold carrier gasket to the upper intake manifold.
Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
NOTE: Apply thread lock compound, to the bolt threads before assembly.
Install or connect the following:
Upper intake manifold. Tighten the upper intake manifold bolts in sequence to 89 in lbs (10 Nm)
Accelerator and the cruise control cables with the bracket to the throttle body.
EVAP purge solenoid vacuum line to the throttle body.
Connect the electrical connectors to the following:
Mass Air Flow (MAF) sensor
Manifold Absolute Pressure (MAP) sensor
Idle Air Control (IAC) valve
Throttle Position (T/P) sensor
EVAP purge solenoid
Install or connect the following:
Throttle body upper support bracket bolt. Tighten the bolt to 89 in lbs (10 Nm)
EGR valve wiring harness heat shield, nut and the bolt. Tighten the nut and the bolt to 89 in lbs (10 Nm)
Take the hypercharger back off. The carb uses fuel according to how much air sucks through. You are putting alot more air through the carb, so it sucks more fuel into the engine. Even if your not burning all the fuel, it's running through anyway. That's the downfall to a carb.
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