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Electra Glide Hypercharger install

Attention! A factory service manual is necessary for 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  This was the first on the first page of the instructions and for it was so true in fact I used a HD Factory manual and a Clymer manual. Ok this what is included in the hypercharger kit are

 

Chrome Hypercharger Assembly/Support Bracket/Breather Hardware Kit, including:/1 1-1/4” Breather Bolts (pr)/1 Breather Hoses (pr)/4 Shim Washers, 0.030 thickness/1 Twin Cam Breather Kit, Including:/1 Breather Adapter/Spacer/1 90° Barbed Fitting 1/8 NPT/2 180° Barbed Fitting 1/4-28/1 16” Vacuum Hose/1 Barbed “T” Fitting/3 1/4-20 x 1-1/2” SHCS, Patched/1 Gasket with Adhesive/2 Gasket without Adhesive/4 4” Nylon Cable Ties/1 Delphi Vacuum Adapter/1 Installation Instructions

This kit is very high quality but it’s not for the faint of heart it a major job, But the results are well worth it. When the butterfly’s open with engine vacuum is so cool

 

STEP 1 I removed the gas cap and dash assembly then siphon the five gallon tank and then removed the crossover hose and all the tank mounting hardware and moved on to a chrome solinoid cover and to wait for the tank to drain

Now the stock air cleaner assembly was to be removed and the breather bolts with the backing plate .

 

Now that the tank was as empty as possible It was time to depressurize the fuel system and to do this, the fuel pump fuse had to be disconnected and the bike started till it stalled

 

By twisting the fuel line quick disconnect and separate the line from the tank.  The fuel tank could be removed so access to the throttle body could be gained

 

The throttle, idle cables and cruise control cable had to be disconnected from the throttle body. The Map sensor (manifold air pressure) and IAC (Idle Air Controller) wiring harness is disconnected.

 

 

 

Remove the IAC bracket; remove the MAP sensor. Assemble the vacuum adapter. Install the rubber manifold air pressure seal onto the adapter body.  Install the vacuum adapter on the MAP sensor.  Had to be sure the orientation of the hose barb is correct

 

Connect one end of the vacuum hose included with the Hypercharger to the hose fitting on the MAP sensor

 

 

Now it was time to Connect the wiring harnesses to the MAP sensor and the IAC unit.

 Reconnected  the throttle, idle cables and cruise control.  Position the chrome support bracket over the mouth of the throttle

body and fasten loosely to each head with the supplied breather bolts.

 

 

Sliding an intake gasket between the support bracket and the throttle Body mouth and making sure all the holes are aligned. Tighten the breather bolts. Trim 1/4” from each end of ONE of the supplied breather hoses. Install this hose between the front head and the 90° fitting on the breatherAdapter. Install the remaining breather hose between the rear breather bolt and The straight barbed fitting on the breather adapter. Securing the ends of the two hoses with the supplied cable ties; trim the cable tie ends. Remove the paper backing from the self-adhesive intake gasket and Apply the gasket between the Hypercharger and the breather adapter.

Install the three supplied 1/4” SHCS into the Hypercharger mounting holes.

 While holding the gaskets in place between the breather adapter, support bracket, and air

Cleaner, secure the assembly to the throttle body. DO NOT over tighten the fasteners;

hand tight plus 1/4 turn with a wrench is sufficient torque to secure the fasteners.

Replace the trap door on the Hypercharger. Connect the vacuum line to the

Air jet on the bottom of the Hypercharger vacuum pod and reinstall the gas tank fuel lines and seat.

This is part of what I consider the HARLEY TAX a stock Electra glide runs so lean and the motor runs so hot. In stock condition when I look at my spark plugs  were just about white Indicating to me that the motor is running lean and hot this cant be good. Well between the power commander and the hypercharge made a noticeable difference.

This is for the many guys who asked about this air system

COMMENTS
Shenresi said at 10:38 a.m. on Mar 27, 2008:
very, very interseting Phil, but sorry, I don`t understand nothingt from technic, but I like to look at those wonderful machines !!!
Roadglide said at 11:01 a.m. on Mar 27, 2008:
Dont be sorry and thank you very much
Roadglide said at 10:47 p.m. on Mar 27, 2008:
Thanks Reta been out the last couple of days
Chiloedream said at 8:16 a.m. on Mar 31, 2008:
Un tabblo très riche techniquement. Merci Phil.
Txcorruptor said at 8:38 p.m. on Jan 22, 2009:
I have an 03 electraglide with this setup. It was installed when I purchased. My question is my baffle is closed while running highways speeds and now I am gettting a vibration noise from baffles. The baffle is open at idle but closes at highway speeds. To me that sounds backwards.
Roadglide said at 8:58 a.m. on Jan 23, 2009:
Hi I had a very similar issue when I was at deals gap ,I have the hyper charger with the ram air attachment Ok I am no expert by any means so take this with a grain of slat Your hyper charger works on a engine vacuum at idol the vacuum is grater then say doing sixty or seventy so the butterfly's wont open all the way and I think that this is normal but check the vacuum lines from the charger to the throttle body ,for cracks and at the nipples. Also take the outer cover off as you were going to clean the air filter hell might as well clean the air filter while your at it any ways. Then check the bolts that attaches the inner charger cover to the throttle body. This is were I bet your vibration is coming from. (I thought my cam tensioners were gone because of this) It was just the inner cover rattling driving me nuts. It took me a while to find this, I the put red lock tight on the bolts and every oil change I clean the filter and check the bolts. Hope this help



Phil Tomaszewski
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