installation manual

AEROCHARGER TURBO SYSTEM
INSTALLATION MANUAL
HARLEY-DAVIDSON FL-SERIES
Version 1.1
R
INTRODUCTION
Congratulations on your purchase of an
Aerocharger Turbo system for Harley-Davidson
FL-Series motorcycles!
You now own the most powerful, reliable, and technologically
advanced turbo system in the world. With your new turbo system
installed, you will experience substantial performance gains. Our
unique system combines VATN technology with our frictionless,
non-flooded ceramic ball bearing system, which provides zero lag
performance.
This system is proudly made and assembled in the USA by Aerocharger LLC.
CONTENTS
Warnings and Disclaimers.................................................................................. i
I. Install The Headers.......................................................................................... 1
II. Turbo And Exhaust........................................................................................ 2
III. Airbox Installation........................................................................................ 5
IV. Charge Tube (Non-Intercooled).................................................................. 6
V. Intercooler And Charge Tubes...................................................................... 6
VI. Replace Injectors........................................................................................... 7
VII. Gauges........................................................................................................... 8
VIII. Fuel Controller......................................................................................... 11
IX. Final ReAssembly........................................................................................ 11
X. Calibrate the AFR Gauge............................................................................. 12
Appendix............................................................................................................ 13
A. Fueling..................................................................................................... 13
B. Engine Upgrades.................................................................................... 13
C. Vehicle Maintenance............................................................................. 13
D. Aerocharger maintenance .................................................................... 13
E. AFR Gauge Guidelines.......................................................................... 14
F. Innovate MTX-L AFR Gauge Error Codes......................................... 14
i | Harley-Davidson FL-Series Turbo System Installation Manual
WARNINGS AND DISCLAIMERS
Any aftermarket power-adding product can be dangerous to a vehicle if
not used as directed. Aerocharger Turbo Systems are properly engineered,
manufactured with high-quality components, and heavily tested to ensure best
possible reliability. However, many factors that are out of our control, such as
installation errors or misuse, can potentially cause damage. When properly
installed and configured, this system should outlast the life of the vehicle.
Please note the following warnings, carefully follow all instructions, and do not
hesitate to contact an Aerocharger tech if you are unclear about any guidelines
listed here.
INSTALLATION WARNING
If you are uncomfortable performing any installation procedure as
described in this manual, please consult a trained professional at a qualified
performance shop. If you are performing the installation of this system
yourself, we recommend reading the entire manual before beginning the
installation. We also suggest that you review your progress after each section to
ensure that everything has been correctly installed.
MODIFICATION WARNING
This system is designed for use on a stock 2008+ Harley-Davidson
FL-Series motorcycle with an undamaged, well-maintained engine. If your
motorcycle is modified, consult with Aerocharger before proceeding.
Aerocharger is not responsible for ECU tuning and programming.
ENGINE BREAK-IN WARNING
Installing turbo systems on brand-new vehicles is not recommended.
New engines require a specific break-in procedure that does not factor in
extra stress from forced induction. If the vehicle is new or has low miles,
consult the dealership or owner’s manual to determine the proper break-in
procedure before continuing with this installation. Failure to do so can result
in significant engine damage.
Aerocharger Turbo Systems | ii
WARNINGS AND DISCLAIMERS, CONT’D
OCTANE:
For best performance and reliability, always use the recommended
octane for your specific setup. See Appendix B for recommended octane.
Always listen for signs of detonation. IF DETONATION SHOULD
OCCUR, OR YOU ARE UNSURE IF WHAT YOU ARE HEARING IS
DETONATION, DECREASE THROTTLE IMMEDIATELY and consult an
Aerocharger technician. If the system is installed, configured, and operated
correctly, detonation will not be an issue. Please note that inconsistencies on
stock engines and parts are possible on any new vehicle from an OEM.
INTERNATIONAL OCTANE: Fuels are described in this manual using the
AKI octane rating system commonly used in North America (RON+MON/2).
Fuels that are sold in Europe and other countries generally use the RON
rating system. If you are located outside of North America, be sure to use the
equivalent octane that is available in your region.
IMPORTANT NOTES
NOTE: Read and understand all safety and technical precautions in this
manual before proceeding. Failure to comply with the instructions in this
manual could result in personal injury, property damage, voided warranties,
and inconsistent or poor performance from the turbocharger system. Contact
Aerocharger with any questions or concerns.
DO NOT hit the rev limiter. This will lead to detonation and cause damage to
the engine.
DO NOT let any debris (hard or soft) enter air intakes or exhaust ports during
installation of this turbo kit.
DO NOT use any silicone sealants except as directed in this manual. Silicone
sealants can cause Foreign Object Damage to the turbo. THIS WILL VOID
YOUR WARRANTY.
AEROCHARGER WILL NOT BE HELD RESPONSIBLE
FOR DAMAGE TO THE VEHICLE’S POWERTRAIN.
1 | Harley-Davidson FL-Series Turbo System Installation Manual
Aerocharger Turbo Systems | 2
I. INSTALL THE HEADERS
1.1 Remove the seat, gas tank, bags, side panels and stock exhaust from the motorcycle.
1.6 Loosely mount the turbo support bracket to the chassis at the back of the header.
1.2 Remove the lower header mount bracket
for ease of installation.
(Two 1/4” allen bolts)
1.3 Reuse the c-clamp from the stock headers
on the new Aerocharger header pipes.
II. TURBO AND EXHAUST
1.4 Loosely mount the Aerocharger header pipes onto the engine exhaust manifold.
1.5
Re-attach
the lower header
mount bracket.
2.1 Set up the 53 series Aerocharger turbo.
Add 1 full bottle of turbo oil included with the kit.
Reinstall the fill plug, using thread lock fluid on
the threads and torque to 35 in-lbs.
(3/16” allen wrench)
Refer to Appendix D for information about
setting and maintaining the Aerocharger.
www.AEROCHARGER.com
(913) 829-3400
[email protected]
www.AEROCHARGER.com
2.2 Install the filter on the compressor housing
and tighten down.
(913) 829-3400
[email protected]
3 | Harley-Davidson FL-Series Turbo System Installation Manual
Aerocharger Turbo Systems | 4
2.3 Place the metal exhaust gasket on the turbo 2.4 Fit the heat shield underneath the turbo,
exhaust flange, then loosely bolt the turbo to the
header using the included hardware. Use the
longer bolts on the bottom to pass through the
turbo support bracket.
and bolt on the muffler flange through the heat
shield.
2.6 Place bolts with rubber grommets through the rear mounting tab on the afterpipe. Attach the
afterpipe to the stock bracket on the rear bag mount, and tighten securely.
2.7 With the turbo, headers and afterpipe
installed, firmly snug up all bolts and connections.
2.5 Place the retaining collar over the afterpipe, then attach the afterpipe to the flange on the turbo.
Tighten down.
www.AEROCHARGER.com
(913) 829-3400
[email protected]
www.AEROCHARGER.com
(913) 829-3400
[email protected]
5 | Harley-Davidson FL-Series Turbo System Installation Manual
Aerocharger Turbo Systems | 6
III. AIRBOX INSTALLATION
IV. CHARGE TUBE (NON-INTERCOOLED)
3.1 Attach the crankcase vent tube assembly to the fittings on the cylinders, and secure with hose
4.1 For non-intercooled systems: Attach the silicone charge tube directly from the turbocharger
clamps or ties. Run the hose along the frame, towards the swingarm.
compressor outlet to the airbox. The end of the charge tube with the blow-off valve will be closest to the
airbox, facing inward. Later, a reference line will be attached to the fitting on the blow-off valve.
V. INTERCOOLER AND CHARGE TUBES
3.2
This 3/16” hose will be used later to
provide manifold pressure readings for the fuel
controller only - the boost gauge will tie into a
T-fitting located off the turbo.
3.3
Use the provided hardware to install the
Aerocharger airbox onto the motorcycle’s throttle
body. Snug securely and evenly, but do not
overtighten the bolts.
3.4 Screw the airbox cover into the recess on
the airbox with the provided hardware.
www.AEROCHARGER.com
(913) 829-3400
[email protected]
5.1 For intercooled systems: The front intercooler bracket bolts to the frame above the left passenger
foot peg. The rear bracket clamps on to the bag support, with an inner rubber grommet to protect the
finish. Use thread-lock fluid on all bolts.
www.AEROCHARGER.com
(913) 829-3400
[email protected]
7 | Harley-Davidson FL-Series Turbo System Installation Manual
5.2
Attach the silicone charge tube with the
blow-off valve from the intercooler to the airbox.
The BOV end will be closest to the airbox, with
the BOV facing inward. Tighten the hose clamps.
Aerocharger Turbo Systems | 8
5.3
Run the 2nd silicone charge tube under
the swingarm. Attach the charge tube to the
Aerocharger compressor outlet and the lower
intercooler port. Tighten the hose clamps.
VI. REPLACE INJECTORS
6.1
(913) 829-3400
6.3
Reinstall the injector harness. Leave the
injector connectors unplugged for now; the fuel
controller will tie into them later. Reinstall the
retaining bracket with the 27mm Torx screw.
VII. GAUGES
Disconnect the injector retaining bracket with a 27mm Torx screwdriver. Unplug the injector
connectors, and pull out the injectors with their harness.
www.AEROCHARGER.com
6.2
Change the stock injectors to the larger
injectors included in the kit. Use silicone grease
to lubricate the o-rings on the injectors when
plugging them in.
[email protected]
7.1
The optional boost gauge and mount
will attach to the brake lever mounting bracket,
replacing the stock cap.
www.AEROCHARGER.com
7.2
Run the boost line from the gauge along
the handlebars, behind the console plastics, and
along the frame. It will plug into a T-Fitting near
the turbo’s vacuum fitting.
(913) 829-3400
[email protected]
9 | Harley-Davidson FL-Series Turbo System Installation Manual
Aerocharger Turbo Systems | 10
7.7 Connect the AFR sensor cable to the AFR gauge plug. Run the cable through the frame toward
the exhaust. There will be plenty of extra length - neatly wrap the excess and tie it off out of the way.
7.3
The blow-off valve will have a stainless steel
braided boost line attached with a t-fitting. Route
the t-fitting and connected lines up under the seat.
The short line will connect to the boost gauge/
manifold pressure t-fitting
7.4
The optional Air-Fuel Ratio gauge will
clamp to the desired location on the handlebars.
7.8
Carefully screw the AFR Sensor into the
bung on the afterpipe and tighten with a 7/8”
wrench. Connect the AFR cable to the sensor.
7.5 Route the AFR Gauge wiring behind the
console plastics as well. One is a power plug, and
the other will attach to the line coming from the
AFR sensor installed in the exhaust.
www.AEROCHARGER.com
7.6 Run power to the AFR Gauge by
connecting the included line to the AFR Gauge
power plug. Run the line along the center frame,
and connect to the accessory power plug on the
factory wiring harness under the seat.
(913) 829-3400
[email protected]
7.9
The AFR gauge will need to be calibrated
before use. After the installation is complete, refer
to Section 10 for the calibration procedure.
www.AEROCHARGER.com
(913) 829-3400
[email protected]
11 | Harley-Davidson FL-Series Turbo System Installation Manual
VIII. FUEL CONTROLLER
An aftermarket fuel controller should be installed at this time to supply additional fuel for boost. Fueling
is not included, as most owners will want to use their preferred fuel controller with this system. All
fuel controllers will tie into the injectors and boost reference line, but installation and features will vary
depending on the controller. Dyno tuning will be required to map the fuel controller to the motorcycle and
turbo system. Contact an Aerocharger tech or dyno tuning specialist for information and recommendations.
X. CALIBRATE THE AFR GAUGE
10.1
The AFR gauge is installed and powered.
Unplug the sensor from gauge and unscrew it from
the muffler bung. Turn on the ignition to power
up the gauge.
10.3
Reconnect the o2 Sensor to the AFR
harness, but leave the sensor uninstalled to
calibrate it to open air.
9.1
9.2
Reinstall the gas tank, seat, bags, side
panels, and any other part that has been removed
during the installation of this turbo system.
www.AEROCHARGER.com
10.2
The AFR Gauge will enter setup mode
and display an “E2” error message. Turn off the
motorcycle and wait several moments for the
vehicle to completely power down.
10.4
Turn on the ignition again. The gauge
will now display “Htr.” After 30 seconds, it will
display “Cal,” and then read “22.4” indicating it
has been calibrated to open atmosphere. The AFR
calibration procedure is complete, and the sensor
can now be installed back in the muffler bung.
This completes the installation. If required, the vehicle may now
be taken to a qualified dyno service for tuning and mapping.
IX. FINAL REASSEMBLY
With the fuel controller installed, re-check
the installation. Verify that all wiring and lines are
cleanly routed, and that all connections are secure.
Aerocharger Turbo Systems | 12
9.3
The fuel controller can be located anywhere
the rider chooses. Aerocharger recommends
having it accessible while becoming familiar with
the system, such as on the tank. Once the system
is fully dialed in, many riders prefer to locate the
fuel controller under the seat
(913) 829-3400
[email protected]
www.AEROCHARGER.com
(913) 829-3400
[email protected]
13 | Harley-Davidson FL-Series Turbo System Installation Manual
APPENDIX
E. AFR GAUGE GUIDELINES
A. FUELING
The Aerocharger turbo system for Harley-Davidson motorcycles has
been designed to operate on 91 Octane fuel available at any gas station.
B. ENGINE UPGRADES
This Aerocharger system is upwardly expandable,
and is able to accommodate engine upgrades for
increased horsepower output. It is important
to note that some aftermarket engine parts
will not work in harmony with this system. A
poor combination of powertrain variables can
reduce efficiency and cost the vehicle overall
horsepower. Consult an Aerocharger technician
for recommendations on components that work
well with Aerocharger-specific applications.
C. VEHICLE MAINTENANCE
Any aftermarket power-adding product can
accelerate wear on a vehicle. However, when
properly configured, operated, and maintained,
the turbo system should outlast the life of the
vehicle. Do not neglect the normal maintenance
schedule for your vehicle and pay attention to
it’s tune and performance, and the Aerocharged
vehicle will easily be capable of thousands of
boosted miles.
Aerocharger Turbo Systems | 14
• AFR numbers are most important to monitor when the engine is under heavy load, such as heavy
acceleration or climbing a hill.
• Monitor your air/fuel ratio to ensure that it stays below 12.8 when the engine is under heavy load.
• The AFR will spike to very lean levels when decelerating. This is normal.
• Sensors should be periodically recalibrated. Always completely remove the sensor from the pipe to
get an accurate reading.
F. INNOVATE MTX-L AFR GAUGE ERROR CODES
D. AEROCHARGER MAINTENANCE
The Aerocharger is a sophisticated and highly efficient variable
vane turbocharger. Unlike conventional turbos, it does not
require oil pumps or lines. The Aerocharger will not need more
maintenance than any other turbo - this graphic contains
information for adjusting the Aerocharger to ensure best
performance.
BOOST SPRINGS
Aerocharger boost springs are used to set the
boost pressure. Every Aerocharger is shipped
with a green 5 PSI spring already installed.
Available springs include:
5 PSI
GREEN
8 PSI
BLUE
ORANGE
6 PSI
GREEN
BLUE
BLUE
9 PSI
ORANGE
7 PSI
11+ PSI
BOOST FITTING
PN # 66335
JAM NUT
BLACK
Shims can be added
to the springs to
increase the boost in
increments of about .5
to . 75 PSI.
R E TA I N I N G C L I P
PN # 66325
PN # 66328
PISTON
PN # 66322
DIAPHRAGM SHIM
PN # 66333
DIAPHRAGM
PN # 66321
CONTROLLER TOP
PN # 66323
AEROCHARGER OIL
Specialized oil for ultra-high rpm machinery.
Only use genuine Aerocharger Turbo Oil.
The wrong oil can lead to bearing failure.
X1
X2
Aerochargers consume oil throughout their use. The
amount of oil consumed is very small, and the oil
level must only be checked once a year or every
30,000 miles. Aerocharger oil never has to be
changed - only added. There is no benefit to
changing the oil unless it has been contaminated
with a foreign substance, such as if the vehicle has
been underwater for a long time.
PN # 66337
CONTROLLER BONNET
SPRING SHIMS
OIL LEVELS
ADD 1 BOTTLE
FOR 53 SERIES
PISTON SHIM
PN # 66342
SPRING SHIMS
PN # 66338
BOOST SPRING
PN # 66341
DUST SHIELD
PN # 66340
ADD 2 BOTTLES
FOR 66 SERIES
Housing
PN # 66326
CONTROL ROD
PN # 66078
NOTE: NEVER attempt to disassemble
the main Aerocharger housings.
The bearing and vane systems
require specialized tools to take it
apart without damaging it. Contact
Aerocharger for all service and
repairs.
www.AEROCHARGER.com
INTEGRATED BOOST CONTROLLER
CHECKING OIL LEVEL
Remove the fill plug and
use a zip tie as a dip stick
to measure the oil level.
HORIZONTAL ORIENTATION
Oil should be added if the
level is lower
1” (2.5 cm)
1/2” (1.3 cm)
than .5” (1.3
cm.)
Oil is full at 1”
height (2.5 cm.)
Use red thread lock fluid on the threads
when replacing the fill plug and tighten
down securely .
VISIT AEROCHARGER.COM
TO SEE A VIDEO TUTORIAL
ABOUT ADJUSTING THE
AEROCHARGER’S BOOST
CONTROLLER TO AFFECT
TURBO RESPONSE
The Integrated boost controller on the Aerocharger is a simple
mechanical actuator where pressure in a chamber pushes against a spring
to move the vanes. It can be easily disassembled to adjust the boost by
changing springs and/or shims. Manual & electronic boost controllers are
compatible with Aerocharger systems, but are not recommended.
(913) 829-3400
[email protected]
www.AEROCHARGER.com
(913) 829-3400
[email protected]
HARLEY-DAVIDSON FL-SERIES
By Aerocharger, LLC
402 New Century Parkway
New Century, KS 66031
(913)829-3400
www.AEROCHARGER.com