null  null
HARLEY-DAVIDSON V-ROD ‘07 – ‘08
SUPERCHARGER KIT (Non USA)
(PATENT PENDING)
INSTALLATION INSTRUCTIONS
Kit Serial #
_________________________
Supercharger Serial # __________________
ECU Serial #
Page - 1 - of 82
Copyright ©
_________________________
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
Table of Contents
IMPORTANT INFORMATION ______________________________________________ - 5 -
SAFETY WARNING ______________________________________________________ - 6 -
WARNING______________________________________________________________ - 6 -
W A R R A N T Y ________________________________________________________ - 7 -
CHANGES TO FACTORY SPECIFICATIONS _________________________________ - 8 -
INTELLECTUAL PROPERTY USED IN THIS PUBLICATION _____________________ - 8 -
RECORD OF AMENDMENTS __________________ ERROR! BOOKMARK NOT DEFINED.
PARTS SUPPLIED – (MAIN BOX) __________________________________________ - 9 -
PARTS SUPPLIED – (MODEL BOX) _______________________________________ - 10 -
SUMMARISED INSTRUCTIONS ___________________________________________ - 11 -
FOR EXPERIENCED VRSC TECHNICIANS__________________________________ - 11 -
SUMMARISED INSTRUCTIONS ___________________________________________ - 12 -
FOR EXPERIENCED VRSC TECHNICIANS CONTINUED ______________________ - 12 -
DISASSEMBLY INSTRUCTIONS __________________________________________ - 13 -
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
:$7(538035(029$/ BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB MODIFICATION INSTRUCTIONS __________________________________________ - 24 -
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
IMPORTANT INFORMATION
PRODUCT WARNING
Installation of the Sprintex® Supercharger kit may void all or parts of Harley-Davidson’s Warranty.
Customers should consult their Harley-Davidson dealer for details. Your Sprintex® Supercharger
installation should only be carried out by an authorised Sprintex® approved supercharger specialist.
Sprintex® makes no representation that installation and use of the Sprintex® supercharger kit is legal for road
use worldwide. Customers should check that installation and use of the Sprintex® supercharger kit is legal by
contacting the relevant statutory authority in their jurisdiction.
Provided in this installation manual are detailed instructions to the installer on how to install the Sprintex®
patent pending supercharger kit to the Harley-Davidson V-Rod. The instructions are aimed at being simple
yet informative, and are aided with well presented pictures to make installations as simple, fast, and problem
free as possible. Please read the entire instruction manual prior to beginning the installation procedure.
Pictures and descriptions may vary slightly from model to model.
It is recommended that all wiring harness connectors, and vacuum hoses are labelled at the time of removal
for easy and correct refitting. Some components that are removed and are to be refitted are fragile, and
should be stored safely to prevent damage to these components.
Sprintex® recommends performing the following vehicle checks prior to installing the supercharger. 1) Check
that the factory fuel system is operating correctly.
2) Inspect the factory exhaust catalyst for blocks or
damage, and 3) Check fuel quality in fuel tank ensuring that it is not stale or low octane fuel. Replace with a
higher octane, 93OCTANE Premium Unleaded Gasoline / Fuel as required.
It is also recommended to
replace the fuel filter if the vehicle has travelled more than 15,000Kms.
Sprintex® will not be liable for any loss, damage, payment, costs, expenses or other liability, not expressly
stated in this document. In particular, Sprintex® shall not be liable to any person for any consequential,
indirect or economic loss or punitive or exemplary damages of any kind.
Sprintex® reserves the right to change specifications from time to time and will not be liable to any person for
doing so. Sprintex® believes that information in this document is correct at time of print. Sprintex® limits its
liability to the maximum extent permissible at law with regard to the reliance which any person places on
anything in this document.
Page - 5 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
SAFETY WARNING
Your Sprintex® supercharger installation should only be carried out by an
authorised Sprintex® approved supercharger specialist. No unauthorised service or
alteration may be undertaken to the Sprintex® supercharger Installation should be
carried out in a workshop which is a safe ventilated working environment with
equipment and procedures compliant with local authority guidelines and legal
requirements. Authorised Sprintex® approved supercharger specialists are required
to hold current worker’s injury insurance. Installers should ensure adequate hearing,
eye, and physical protection is used at all times during the installation process.
Installers should take reasonable precautions to avoid fatigue and closely follow the
installation instructions during every installation. Sprintex® recommends installation
should not be carried out unsupervised. Sprintex®, its directors, employees and
agents will not accept liability for damage accident or injury resulting from the
installation process. Safety warnings are provided throughout this document
indicated by a L.
WARNING
THIS SPRINTEX® INSTALLATION REQUIRES A STANDARD HARLEY-DAVIDSON FACTORY ECU
CALIBRATION TO BE INSTALLED PRIOR TO THE INSTALLATION OF THE SPRINTEX®
SUPERCHARGER KITÊ. FAILURE TO ENSURE THIS WILL AFFECT THE PERFORMANCE AND MAY
VOID YOUR WARRANTY.
SHOULD YOU BE UNSURE RETURN YOUR MOTORCYCLE TO YOUR NEAREST HARLEY-DAVIDSON
DEALER TO ENSURE THE STANDARD CALIBRATION HAS BEEN REINSTATED AND IS OPERATING
CORRECTLY.
SAFETY WARNING!
Do not start or run your Sprintex® VRSC Supercharged Motorcycle
without the Belt cover installed – Belt or pulley failure without the
Belt cover installed may result in injury, accident or death.
Sprintex® supports safe riding so always remember to observe all speed limits and road rules relevant
to your state or city. Always wear appropriate safety equipment when riding.
WARNING: Fitment of this kit to your Harley-Davidson V-Rod may affect the manufacturer’s warranty.
Customers in doubt should check with their Dealer. Sprintex® does not warrant that purchase, use or
installation of this kit is legal for use worldwide. Customers should refer to their statutory authority in
their local jurisdiction prior to using this kit for public road use.
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
WAR RAN TY
1.
WARNING
Your Sprintex® VRSC supercharger system installation should be carried out by an authorised Sprintex® approved supercharger
specialist for your warranty to apply. No unauthorised service or alteration may be undertaken to the Sprintex® supercharger system or
standard motorcycle specification.
Any modification or alterations from the Sprintex® or Harley-Davidson specification will void your WARRANTY. (Refer to clause 7)
2.
FUEL SPECIFICATION V-ROD
USA
Europe
Australia
New Zealand
Minimum 93 OCTANE Premium Unleaded Gasoline / Fuel
Minimum 95 RON Premium Unleaded Petrol
Minimum 95 RON Premium Unleaded Petrol
Minimum 95 RON Premium Unleaded Petrol
WARNING
SPRINTEX® ADVISES THAT THE USE OF ETHANOL BLENDED FUELS MAY CAUSE DAMAGE TO YOUR ENGINE.
THEREFORE USE OF ETHANOL BASED FUELS IS NOT RECOMMENDED.
IN CIRCUMSTANCES WHERE ETHONOL BLENDED FUELS ARE UNAVOIDABLE, SPRINTEX® RECOMMENDS THAT
THE USER MODIFIY THEIR DRIVING STYLE ACCORDINGLY AS WARRANTY DOES NOT EXTEND TO DAMAGE
CAUSED BY THE USE OF ETHANOL BLENDED FUELS.
3.
SUPERCHARGER BELT & PULLEY
Must be inspected at every routine service and the belt replaced when required.
4.
OIL SPECIFICATION (ENGINE ONLY)
Harley-Davidson
Type
HD Multigrade
HD Multigrade
Viscosity
SAE10W40
SAE20W50
Harley-Davidson
Rating
HD360
HD360
Lowest Ambient
Temperature
Below 40°F (4°C)
Above 40°F (4°C)
Cold Weather Starts
Below 50F (10C)
Excellent
Good
5.
SPRINTEX® VRSC SUPERCHARGER SYSTEM
The Sprintex® VRSC supercharger system WARRANTY provides a guarantee against any manufacturing defect in the parts supplied during
the warranty period.
The warranty guarantees the replacement of any parts of the supercharger installation which fail as a result of a manufacturing defect in
normal operation conditions.
6.
WARRANTY PERIOD
New Bike
12 months (from date of purchase)
Used Bike
6 months (from date of purchase)
7.
TERMS OF WARRANTY
Any and all products returned for warranty purposes must be returned freight pre-paid. Sprintex® is not responsible for any freight or handling
charges on warranted products returned to Sprintex®. If the products are warranted, Sprintex® will pay for ground shipping charges only to
return the parts to the customer. This warranty is for a specific time period only and does not apply to actual operational time or distance. It
does not cover products which fail due to alteration, disassembly, accident, racing, misuse, neglect, improper installation, abuse or when used
in applications for which they were not designed or approved. Sprintex® shall not be liable for non Sprintex® products that have been
purchased through Sprintex® and all warranties will be at the sole discretion of the original manufacturer. Sprintex® makes no representation
as to the suitability of any products purchased for uses implied by the customer. Removal, installation, transportation, labour, loss of time,
inconvenience, destruction of other components and personal damages are not covered. Sprintex® shall not be liable for any and all
consequential damages occasioned be the breach of any written or implied warranty pertaining to a sale in excess of the purchase price of the
product sold.
8.
LIMITATION OF LIABILITY
Except to the extent that a warranty is imposed by an applicable law and cannot be excluded, Sprintex® gives no other warranty either
express or implied as to any matter whatsoever concerning the Sprintex® VRSC supercharger system. Sprintex® limits it’s liability under any
such warranty to the maximum extent permitted.
9.
WARRANTY CLAIMS must be lodged with your authorised Sprintex® approved supercharger specialist and must be accompanied by proof
of purchase.
*THIS WARRANTY IS NOT TRANSFERABLE
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
CHANGES TO FACTORY SPECIFICATIONS
FUEL: MINIMUM 93 OCTANE PREMIUM UNLEADED GASOLINE/FUEL TO BE USED AT ALL TIMES.
NEVER ALLOW THE ENGINE TO KNOCK OR DETONATE AS SERIOUS ENGINE DAMAGE MAY
OCCUR.
SPARK PLUGS: NGK DCPR9E SPARK PLUGS. PLUG GAP TO BE SET TO 0.62mm/0.025”
REQUIRED SERVICE: (SEE MAINTENANCE SECTION OF MANUAL)
1.
INSPECT SUPERCHARGER DRIVE BELT AT EVERY ROUTINE SERVICE AND REPLACE
WHEN REQUIRED.
2.
CHECK SUPERCHARGER OIL LEVEL AT EVERY ENGINE OIL SERVICE.
3.
DRAIN AND REPLACE SUPERCHARGER OIL AT EVERY SPARK PLUG SERVICE.
IT IS
REQUIRED TO REMOVE SUPERCHARGER TO CHANGE OIL AND REMOVE SPARK PLUGS.
USE
REDLINE
EQUIVALENT.
75W/90
HIGH PERFORMANCE
FULLY SYNTHETIC
GEAR OIL
OR
IT IS CRITICAL NOT TO OVERFILL SUPERCHARGER GEARBOX AS
DAMAGE WILL OCCUR. ONLY FILL UNTIL OIL DRAINS FROM LEVEL PLUG AT BOTTOM
EDGE OF SUPERCHARGER GEARBOX COVER.
Intellectual Property used in this Publication
Sprintex® is a registered trademark of Sprintex® Australasia Pty Ltd, a wholly owned subsidiary of Automotive
Technology Group Pty Ltd both companies are incorporated in Australia. This document is copyright of Automotive
Technology Group Pty Ltd, and is not a public document. This document may not be re-sold, copied or distributed in any
way without prior written authorisation of a director of Automotive Technology Group Pty Ltd. This document remains the
property of Automotive Technology Group Pty Ltd and must be returned on request.
Sprintex® has patents for its supercharging system pending. Any unauthorised copying or modification of the system
may result in legal action.
Harley-Davidson and V-rod are registered trademarks of Harley-Davidson Motor Company, a subsidiary of HarleyDavidson, Inc. incorporated in Wisconsin, United States of America. Harley-Davidson does not have any association with
Sprintex® or its related companies, and have not authorised fitment of the Sprintex® supercharger system (patent
pending).
Gates is a registered trademark of the Gates Rubber Company, a subsidiary of Tomkins Plc, incorporated in London,
United Kingdom. Other than commercial supply arrangements, Gates and Tomkins Plc do not have any association with
Sprintex® or Automotive Technology Group Pty Ltd.
Loctite® is a registered trademark of Henkel KGaA, a company incorporated in Dusseldorf, Germany. Other than
commercial supply arrangements, Loctite® and Henkel KGaA do not have any association with Sprintex® or Automotive
Technology Group Pty Ltd.
Red Line is a registered trademark of Red Line Synthetic Oil Corporation, a company incorporated in California, United
States of America. Other than commercial supply arrangements, Redline and Red Line Synthetic Oil Corporation do not
have any association with Sprintex® or Automotive Technology Group Pty Ltd.
Page - 8 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
PARTS SUPPLIED – (Main Box)
1
Sprintex® Supercharger Kit Ê
2
Joiner blocks / spark plugs
10
Supplementary Injection System
3
Belt tensioner / air filter
11
Radiator cap assembly
4
Drive shaft
12
Drive Belt
5
Support brace
13
Cooling Assembly
6
Drive body
14
Drive Shaft Tool
7
Supercharger Drive Pulley
9
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Copyright ©
Breather Hoses
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
PARTS SUPPLIED – (Model Box)
Installation Manual
8
Wiring Loom
Owners Manual
8
Supplementary ECU
Sprintex® Key Fob
15
Sprintex Badges
Coolant Bottle with Hose
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Copyright ©
Belt Cover
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
SUMMARISED INSTRUCTIONS
FOR EXPERIENCED VRSC TECHNICIANS
Note: Alarm immobiliser must be kept in proximity of bike during installation process to prevent alarm going
off or to disable alarm turn ignition on then off and remove maxi fuse within 5 seconds.
DISSASSEMBLY
1.
2.
3.
4.
Remove fusible link
Drain coolant
Drain engine oil
Remove air box and air filter, remove the air temperature sensor and cylinder head breather rubber
(only on later models) from air box for use later
5. Remove battery
6. Remove throttle body assembly
7. Remove horn
8. Remove complete exhaust system (unplug oxygen sensors at harness)
9. Remove coolant filler hose and tube (details in Section 12 page 21)
10. Remove water pump
11. Remove front and rear spark plugs. Replace with spark plugs supplied in kit
12. Remove alternator cover and place to side.
13. Remove TPS sensor, idle air valve, front cylinder throttle plate and front cylinder throttle shaft from
throttle body as described in Section 6 page 30
MODIFICATION
1.
2.
3.
4.
Modify fuel system and fit fuel hose supplied in Bag 10 as described in Section 1 page 24
Modify breather as described in Section 2 page 30
Using tool supplied in Bag 14 remove water pump shaft as described in Section 14 page 49 / 51
Replace water pump shaft with new shaft supplied in Bag 4 as described in Section 14 page 51
(NOTE: please take care and read Section 14 page 48)
5. Install drive body supplied in Bag 6 as per instruction in Section 1 page 54 (NOTE: DO NOT INSTALL
HD WATER PUMP GASKET)
6. Install drive pulley supplied in Bag 7 taking careful note of torque and Loctite® specification described
in Section 3 page 55
7. Refit alternator
8. Install water pipe and water pump supplied in Bags 11 & 13 as described in Section 4 page 55
9. Install battery as described in section 5 page 57
10. Modify HD wiring loom as described in Section 6 page 59, using extensions supplied in Bag 8 (Model
Box)
11. Modify earth / ground connection as described in Section 12 page 45
12. Install Sprintex® wiring loom and supplementally ECU supplied in Bag 8 as described in Section 13
page 45
13. Remove the throttle body from Sprintex® supercharger Section 5 page 36
14. Assemble throttle shaft, throttle plate, idle air valve and TPS sensor previously removed from Harley
throttle body into Sprintex® throttle body as described in Section 6 page 37 (new throttle plate screws
provided in Bag 2). Adjust throttle plate rest position as described in Section 6.17 page 41. Do not
install throttle body to supercharger at this stage
15. Install joiner block supplied in Bag 2 to supercharger assembly as described in Section 11 page 44
16. Install supercharger assembly as described Section 7 page 60
17. Install mounting bracket supplied in Bag 5 as described in Section 2 page 55 Secure bracket to
supercharger using remaining bolts from Bag 5
Page - 11 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
SUMMARISED INSTRUCTIONS
FOR EXPERIENCED VRSC TECHNICIANS continued
18. After fitting main body of supercharger, connect throttle cables to Sprintex® throttle body then install
throttle body to supercharger using silicone sealant as described in Section 10 page 43
19. Install belt tensioner supplied in Bag 3 as described in Section11 page 70
20. Install belt as described in Section 12 page 70
21. Install belt cover supplied in Bag 15 as described in Section 15 page 72
REASSEMBLY
1. Refit exhaust system
2. Fill crank case with engine oil as recommended by Harley Davidson
3. Fill cooling system with coolant recommended by Harley Davidson, bleed air from cooling system as
described in VRSC manual
4. Refit fusible link
5. Reset ECU as described Section 18 page 74
6. Start and test run engine
NOTE: BEFORE RUNNING MOTORCYCLE ON CHASSIS DYNO RIDE THE MOTORCYCLE IN A
‘NORMAL’ MANNER FOR 5 – 10 MINUTES TO ALLOW LEARN FUNCTIONS IN THE HD ECU TO
COMPENSATE FOR CHANGE OF OPERATING PARAMETERS. IDLE QUALITY MAYBE POOR
UNTIL ECU HAS COMPENSATED.
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGER KITÊ
SECTION 1
DISASSEMBLY INSTRUCTIONS
Page - 13 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
DISASSEMBLY PROCEDURES
1. Preparation
1.1
Ensure bike is located in a secure position.
Sprintex® recommends to avoid injury you
should secure the bike on a scissor lift or
similar bike stand using straps at anchor
points provided.
2. Purging Fuel System
LSAFETY WARNING: Fuel system is under high
pressure.
To prevent uncontrolled fuel spray
during installation, it is required to purge the
system of high pressure fuel. INADEQUATE
SAFETY PRECAUTIONS COULD RESULT IN
PERSONAL INJURY OR DEATH. ENSURE NO
POTENTIAL OF EXTERNAL IGNITION SUCH AS
NAKED FLAMES, WELDING OR SPARKS ARE
OCCURING IN THE VICINITY PRIOR TO
COMMENCING
THIS
PROCEDURE.
YOU
SHOULD ENSURE YOU ARE WEARING EYE
PROTECTION
AND
LOW
COMBUSTIBLE
CLOTHING PRIOR TO COMMENCING THIS
PROCEDURE. IT IS RECOMMENDED TO KEEP
AN
APPROPRIATE
TYPE
OF
FIRE
EXTINGUISHER READILY AVAILABLE.
2.1
Lift seat.
2.2
Disconnect fuel module connector from fuel
tank top plate (1).
2.3
Start engine and allow to run.
2.4
When engine stalls, continue to turn engine
over for approximately 3 seconds using the
starter to remove any fuel pressure from the
fuel lines.
LSAFETY WARNING: Allow engine to cool prior
to proceeding with disassembly to prevent
scalding.
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
DISASSEMBLY PROCEDURES
3. Maxi-fuse Removal
3.1
LSAFETY WARNING: ensure the bike is
not running and the ignition key is in the off
position for the remainder of the disassembly
procedure.
3.2
To disarm alarm, turn ignition to on then off
and remove maxi fuse within 5 seconds.
3.3
Remove fastener (1) and remove RH side
battery cover (2).
3.4
Remove maxi-fuse and store safely.
4. Air box, Intake Air
Temperature Sensor And Air
Filter Removal
4.1
Remove air box cover by turning retaining
fastener ¼ turn counter clockwise. Pull air
box cover away from locating holes.
4.2
Place cover in a safe place away from
potential damage.
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
4.3
Remove
connector from
Intake
Air
Temperature Sensor (IAT) (1). The sensor
will be used later in the installation.
4.4
Unclip 8 clips (2) retaining air box top, and
remove air box top. There are three clips on
each side, one on the front and one at the
back.
4.5
Remove wing-nut securing air filter and
remove air filter from air box.
4.6
Disconnect breather hose (1).
4.7
Slide o-rings (2) up velocity stacks and
remove 3 cap screws securing each stack.
4.8
Remove velocity stacks.
4.9
For models with moulded breather hoses,
front breather hose is a press fit, and
disconnects when air box base is lifted. Rear
breather needs to be disconnected from
oil/air separator and pushed out of air box
base. Lift base to remove.
DISASSEMBLY PROCEDURES
1
2
1
4.10 For other models, the front breather is
retained by a worm clip, loosen clamp. Rear
breather is secured to air box bottom with a
worm clip. Loosen clamp, disconnect hose
and remove air box bottom.
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Copyright ©
2
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
DISASSEMBLY PROCEDURES
4.11 Cover the throttle body intakes to prevent
contaminants / objects from falling down the
throttle bores.
5. Battery Removal
NOTE: Always disconnect negative battery cable
first. This prevents possible shorting and potential
battery damage.
5.1
Remove negative (-) terminal bolt first, then
remove positive (+) terminal bolt.
5.2
Remove battery cable clip and remove
battery.
6. Horn Removal
6.1
Remove acorn nut and washer securing horn
to chassis.
6.2
Disconnect two wires from rear of horn and
place horn in a safe place.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
DISASSEMBLY PROCEDURES
7. Throttle Body Removal
7.1
Disconnect throttle position sensor connector
(1).
1
7.2
Disconnect idle air control (IAC) motor
connector (2).
7.3
Loosen clamps securing throttle
(Rocker-covers shown removed)
7.4
Remove throttle body by gently rocking whilst
pulling upwards.
2
body.
NOTE:
•
After removing throttle body, tape up inlets
with tape to prevent any debris from falling
into engine risking engine damage.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
7.5
DISASSEMBLY PROCEDURES
Remove throttle cable housings from guides
at throttle body and remove cable barrels
from throttle cam.
8. Coolant Removal
8.1
LSAFETY WARNING: Allow cooling system
to cool prior to commencing this procedure.
Ensure you are wearing appropriate
protective clothing to prevent scalding. When
removing pressure cap use a cloth to prevent
spillage and scalding.
8.2
Using a cloth over pressure cap, turn ¼ turn
counter clockwise to safety stop and allow
pressure to relieve.
Remove cap once
pressure has escaped.
8.3
Remove LH radiator cover, by removing
5mm button head screw from underside of
cover, and lifting gently.
8.4
Place container under radiator and remove
radiator drain plug (1) and allow coolant to
drain completely.
8.5
Once coolant has completely drained,
replace radiator drain plug. Tighten plug to
9-11Nm.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
DISASSEMBLY PROCEDURES
9. Coolant Bottle Removal
9.1
Disconnect overflow pipe from water
manifold filler neck being careful not to spill
coolant onto bike (see 13 Page 22).
9.2
Disconnect breather pipe from top of coolant
bottle.
9.3
Remove coolant bottle by lifting vertically to
release locating lugs from rubber grommets.
10. Engine Oil and Filter
Removal
10.1 Place a suitable container under oil drain
plug at front of oil pan on left hand side.
10.2 Remove engine oil drain plug and allow oil to
drain completely.
10.3 Once oil has drained completely, install drain
plug and tighten to 35Nm (25.8ft/lb)
NOTE:
It is recommended, but not compulsory to change
the oil filter.
10.4 Remove engine oil filter using the Oil Filter
Wrench HD-44067.
10.5 Clean filter sealing surface on engine.
10.6 Lube seal on new oil filter, and install new
filter. Tighten filter 2/3 to 1 turn after the
filter’s seal has contacted the mounting
surface.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
DISASSEMBLY PROCEDURES
11. Primary Drive Cover
Removal
11.1 Remove three cap screws securing primary
drive cover and remove cover.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
DISASSEMBLY PROCEDURES
12. Exhaust System Removal
12.6 Remove lower fasteners (1) securing auxiliary
volume and muffler to the exhaust support
bracket.
Note location of L bracket when
Remove the fastener (1) holding the upper
removing front lower fastener.
muffler (25) to the lower muffler (26).
12.7 Remove three 5mm cap screws from right hand
Slide upper muffler rearward separating from
side drive sprocket cover and remove cover.
auxiliary volume (24).
12.8 Remove oxygen sensor cable bracket (29) and
Remove both heat shields (21, 20) from front
disconnect oxygen sensors at harness.
and rear header pipes (10, 9)
12.9 Remove four hex nuts (4) securing front and rear
Remove hex-nut (4) and pin (11) on exhaust
headers to cylinder heads.
support bracket.
12.10 Remove header pipes with the auxiliary volume
and lower muffler all attached. Lift and adjust the
assembly until header pipes slide out and away
from the cylinder heads.
12.1 Loosen upper muffler clamp (18).
12.2
12.3
12.4
12.5
NOTE: To maintain the alignment of all the
components, keep the lower muffler, auxiliary
volume, exhaust clamp and the front and rear
header pipes firmly connected.
13. Coolant Hose Removal
13.1 Loosen and remove hose clamp (4).
13.2 Loosen and remove cap screw (7) securing
P-clamp (8) to engine. Remove P-clamp.
13.3 Loosen hose clamp (12) at bottom of hose
connected to water pump.
13.4 Using a thin screwdriver, loosen hose clamp
(12) and pull hose (13) off radiator.
13.5 Remove engine coolant pipe (2).
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
DISASSEMBLY PROCEDURES
14. Water Pump Removal
14.1 Unbolt 6 water pump cap screws and remove
water pump cover.
14.2 Remove the water pump insert.
14.3 Using a soft mallet, tap on side of water
pump to break seal.
14.4 Remove water pump by gently pulling
outwards.
NOTE:
Ensure to remove water pump gasket which fits
between water pump and crankcase, and discard.
DO NOT RE-INSTALL THIS GASKET.
Page - 23 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGER KITÊ
SECTION 2
MODIFICATION INSTRUCTIONS
Page - 24 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
1. Fuel System Modification
LSAFETY WARNING: Residual pressure may
be released when the fuel system check
valve is removed. You should ensure you
are wearing appropriate protective face
and body clothing and take steps to
minimise spillage and fire. Avoid being in
the potential path of the fuel release.
1.1
Remove fuel rail from the bike.
1.2
Remove fuel system check valve from fuel
rail.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
1.3
Remove the fuel pressure regulator by
removing the two side screws from the
clamp.
1.4
Tap the hole in the fuel pressure regulator
with an M5 tap.
MODIFICATION PROCEDURES
Note: Do not screw the tap too far in the
regulator body as it will damage the
internal spring.
1.5
Clean and dry the pressure regulator using
low pressure air.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
1.6
Put a tiny amount of Loctite 222 on the
thread of the quick-fit connector elbow and
screw it to the fuel pressure regulator.
1.7
Lubricate o-rings on the fuel regulator and
reinstall it to the fuel rail. (Secure regulator
with the clamp and two screws which were
removed previously.)
1.8
Using supplied fuel supply hose, banjo bolt
and 2 5/16” copper washers (from Bag 10)
secure the fuel supply hose to fuel rail in
place of the check valve (previously
removed).
1.9
Route supplied fuel hose under fuel rail.
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Copyright ©
MODIFICATION PROCEDURES
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
1.10 Lubricate fuel injector o-rings and reinstall
fuel rail to the bike.
1.11 Ensure supplementary injector hat is
aligned as shown. Tighten fuel hose banjo
bolt to 11Nm/8.3ft/lb.
Page - 28 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
1.12 Secure the fuel rail in position.
1.13 Connect supplied Teflon pipe to quick-fit
elbow on the fuel pressure regulator.
2. Breather Modification
2.1
For later models using softer 5/16”
moulded hose, the breather system does
not need to be modified. However, the
front rocker cover breather will need to be
refitted to the supercharger assembly, as
described later in this section. (Breather
hose pictured). The rear rocker cover
breather will also need to be removed from
the air box and refitted to the rear rocker
cover breather outlet.
Page - 29 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
For 5/16” Moulded Breather Model
2.2
Remove front cylinder moulded breather
hose from oil air separator in air box base.
2.3
Press moulded breather hose out through
base of air box to remove, and set aside.
2.4
Fit removed breather hose to breather
bracket and fitting on supercharger as
pictured.
2.5
Secure breather hose to brass fitting with a
cable tie.
2.6
Ensure breather hose is correctly located
in breather bracket, and not kinked at any
point.
3. Spark Plug Replacement
3.1
Remove front and rear coil fasteners.
3.2
Detach coil connectors
3.3
Pull coil and boot assembly straight up to
disconnect spark plug.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
3.4
MODIFICATION PROCEDURES
Remove spark plugs using correct spark
plug socket
NOTE:
Check spark plug gaps on supplied spark plugs,
Part No. DCPR9E, are set to 0.62mm/0.025”.
3.5
Install new plugs and tighten to 23Nm
(16.9ft/lb).
3.6
Install coil and boot assemblies over plugs
with wiring connector facing rear of
motorcycle.
3.7
Insert coil fasteners with longer fastener
used on left hand side. Tighten fasteners
to 9.7Nm (7.2ft/lb).
3.8
Connect connectors to coils.
4. Throttle Body Disassembly
4.1
Remove two security screws (1) securing
Throttle Position Sensor to throttle body.
Remove sensor and set aside.
1
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
4.2
MODIFICATION PROCEDURES
Remove countersunk screws securing TPS
plate to throttle body by heating the bosses
under the TPS to break Loctite®.
1
4.3
Using a heat gun, gently heat Idle Air
Control screws (1) to break Loctite® patch
and remove screws.
4.4
Pull IAC and O-ring from throttle body. Set
IAC aside.
1
4.5
Remove circlips from the three posts
shown.
4.6
Remove two washers from lower two
posts.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
4.7
Take note of spring tail location on throttle
swing arm.
4.8
Remove bush from throttle assembly.
4.9
Disconnect throttle arm from top post.
MODIFICATION PROCEDURES
4.10 Remove throttle swing-arm by rotating front
throttle shaft clockwise and lifting upwards.
4.11 Remove swing-arm spring and spring
carrier.
Page - 33 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
4.12 Heat security screws securing swing arm
plate and remove screws.
1
4.13 Heat security screw securing cable guide
to throttle body and remove guide.
1
NOTE: Some butterfly screws have been staked
peened on the backside, and will need the
protruding portion of the thread ground off with a
die grinder or similar prior to removal.
1
4.14 Heat front butterfly screws with a heat gun.
4.15 Remove front cylinder butterfly from
standard throttle body assembly by
removing the 2 security fasteners.
Page - 34 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
4.16 Remove circlips securing front throttle shaft
ensuring not to damage the nylon washer.
4.17 Remove nylon washer from front throttle
shaft.
4.18 Remove throttle shaft and set aside
5. Throttle Body Removal
NOTE 1:
It is easier to fit the previously removed
throttle
linkages
to
the
Sprintex®
supercharger kit with the supplied throttle
body removed from the supercharger kit.
5.1
Disconnect vacuum hose from bypass
actuator as indicated at (1).
5.2
Disconnect breather hose from throttle
body (2).
5.3
Disconnect vacuum line from 3/16” fitting
as pictured.
Page - 35 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
5.4
Remove the 4 M5 cap screws securing
bypass elbow to supercharger kit.
5.5
Remove the 5 M6 cap screws securing
throttle body to supercharger kit, and
remove throttle body. Note position of
different length screws for reassembly.
MODIFICATION PROCEDURES
6. Throttle Body Assembly
NOTE:
The throttle body now needs to be assembled
using the previously removed throttle linkage
components and throttle butterfly. This section
may appear complicated and require practice to
master.
Page - 36 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
6.1
Secure throttle linkage bracket on
supercharger throttle body using 2 supplied
M5x12 countersunk screws from Bag 2.
Tighten to 6Nm (4.4ft-lb)
6.2
Insert throttle shaft and spring into supplied
throttle body.
6.3
Ensure throttle return spring is temporarily
located as pictured.
MODIFICATION PROCEDURES
NOTE:
It is necessary to assemble the swing arm and
throttle shaft at the same time, but for ease of
description, the following pictures show the
throttle shaft not installed.
6.4
Place swing arm plastic spring carrier and
swing arm spring onto post and align as
pictured.
6.5
Take careful note of the location of the
spring ends.
Page - 37 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
6.6
Using previously removed swing-arm,
insert swing arm spring tag through hole in
between the two throttle cable barrel
mounting holes as pictured.
6.7
Position swing-arm onto post, and rotate
clockwise.
6.8
Gently push swing arm down, until the stop
tag on the underside locates in the cut-out
in the throttle body.
MODIFICATION PROCEDURES
NOTE:
It may take some adjusting of the location of the
plastic spring locator before the swing arm will sit
down in its position properly.
6.9
Once swing arm is located properly it
should look like the picture. The swing arm
should have a light pretension on the
spring, and should rest against its stop in
the shown position.
6.10 As the throttle shaft should have already
been installed, it is important that the swing
arm is located over post as pictured.
Page - 38 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
6.11 Place washer over swing-arm post and
secure assembly in position with previously
removed circlips.
6.12 Insert previously removed bush, washer
and circlips onto throttle arm post.
6.13 Rotate throttle return spring, and lift over
post to position shown in picture.
6.14 Secure throttle shaft in throttle body using
supplied E-clip from Bag 2 and nylon
washer previously removed from throttle
body.
Page - 39 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
6.15 Install throttle butterfly to throttle shaft
using new screws supplied in Bag 2.
NOTE: Ensure to use Loctite ® or similar locking
compound to security screws prior to
fitting.
6.16 Ensure throttle assembly rotates smoothly
and returns to correct position.
6.17 Adjust the idle position of the throttle
butterfly, by adjusting the screw on the
throttle body to give a rest position of .003.004" throttle plate clearance.
NOTE 1: It may be necessary to adjust this
clearance after the installation if the engine does
not idle properly. Too little clearance and the
engine will want to stall. Too much and the
engine will flair, taking time to return to desired
idle speed.
NOTE 2:
In some instances harmonic
vibration has been found to cause the
adjustment screw to move hence it is
recommended to apply wick-in Loctite®, or
similar, once the set up is complete.
7. Idle Air Control (IAC) Valve
Installation
7.1
Insert IAC valve and O-ring into throttle
body and secure with 2 supplied
M4x12mm cap screws from Bag 2.
Tighten screws to 3Nm (2.2ft-lb)
7.2
Ensure IAC is aligned as pictured.
Page - 40 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
8. Throttle Position Sensor
Installation.
8.1
Fasten throttle position sensor mounting
plate to throttle body using 2 M5x12
supplied countersunk screws from Bag 2.
Tighten screws to 6Nm (4.4ft-lb)
8.2
Ensure plate is fixed as pictured.
8.3
With connector facing side of throttle body
as shown, verify that shaft pocket of TP
sensor fits over shaft on throttle body.
8.4
Align holes in throttle body plate.
8.5
Fasten TPS to TPS mounting plate using
supplied M4x12 cap screws from Bag 2.
Tighten screws to 3Nm (2.2ft-lb)
8.6
Ensure that there is a light preload on the
TP sensor when it is aligned as pictured.
The TPS can be incorrectly mounted but
still be aligned as shown, and will result in
poor engine operation.
9. Intake Air Temperature
Sensor (IAT) Installation
9.1
Press IAT sensor into throttle body as
shown. Take care not to damage the oring.
Page - 41 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
10. Throttle Body ReInstallation
10.1 Apply a gasket sealant to the highlighted
surface as shown in picture.
10.2 Loosely fasten throttle body to inlet
manifold using previously removed cap
screws and schnor washers. Ensure not to
cross-thread
screws
which
may
permanently damage the manifold and
affect performance.
1. M6x45
2. M6x55
3. M6x55
4. M6x65
5. M6x70
10.3 Apply Gasket Sealant to both contact
surfaces of bypass elbow.
Page - 42 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
10.4 Fit bypass elbow and secure using
previously removed fasteners.
Do not
tighten fasteners yet, just tighten enough
for faces to contact throttle body and
plenum top.
10.5 Gently tighten the five M6 cap screws
securing throttle body to the intake
manifold. Tighten to 10Nm (ft-lb).
10.6 Tighten 4 M5 cap screws securing bypass
elbow to 6Nm (4.4ft-lb)
10.7 Connect breather line to bottom hose
quick-fitting.
10.8 Top actuator must be connected to fitting
furthest from IAT sensor, located on side of
intake manifold. (Red Line)
10.9 Fitting next to IAT on throttle body, must be
connected to lower actuator on other side
of supercharger. (Blue Line)
10.10 Ensure MAP line has not been accidentally
disconnected from fitting on plenum top.
(Green Line)
11. Joiner Block Fitting
11.1 From Bag 2, remove the joiner block, one
M5x40 (1), one M5x65 (2) and two schnor
washers.
1
2
11.2 Fit to base of supercharger plenum as
pictured. Ensure that the front face of the
joiner block is flush with, and square to the
adjoining plenum face.
11.3 Fasten cap screws to 6Nm (4.4ft-lb)
Page - 43 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
12. Earth Bolt Removal
12.1 It is necessary to remove the front and rear
cylinder head earth bolts, as this is used to
mount the supercharger kit.
NOTE:
The earth straps will need to be mounted at the
bottom of the supercharger mounting bolts.
13. Plenum Mounting Bracket
Fitting
13.1 Locate earth straps on to shoulder bolts
and fit mounting bracket to front and
rear cylinder heads. Do not tighten
bolts until both are fitted.
Note:
It is important to locate the two earth strap
eyelets, one on either bolt, underneath. The
eyelets will be located between washer and
cylinder head.
13.2 Tighten bolts to 15NM
Page - 44 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
14. Wiring Loom Modification
NOTE:
Due to the relocation of some of the engine
management sensors, it is required to install
wiring loom extensions supplied in Bag 8.
1
IAC Loom Extension (1)
This loom is supplied with 4 coloured wires.
2
TPS Loom Extension (2)
This loom is supplied with 3 coloured wires, with
a break-out loom and connector.
14.1 Remove the plastic conduit from the IAC
loom and TPS looms as pictured.
IAC Loom Extension
14.2 Factory IAC connector has letters on the
plug defining each of the wires connected
to it.
14.3 These will be connected to each of the
wires on the supplied extension.
Page - 45 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
14.4 Cut wire (A) at IAC connector on factory
loom.
14.5 Strip 10mm of the outer insulation.
14.6 Slide over supplied heat shrink from Bag 8.
14.7 Solder to wire A of the extension.
14.8 Repeat the above for wire B, C and D while
taking care not to touch the soldering iron
against any other parts.
Note: Cut one wire at a time and join to the
corresponding wire from the extension loom
(A-A, B-B, C-C, and D-D).
LSAFETY WARNING: Ensure you are wearing
appropriate protective clothing such as eye
protection and gloves and follow manufacturer’s
safety instructions prior to using a soldering iron.
14.9 Slide up heat shrink over soldered joint and
shrink using a heat gun. Do not use a
naked flame as heat shrink may melt.
Page - 46 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
TPS Loom Extension
14.10 Factory TPS connector has letters on the
plug defining each of the wires connected
to it
14.11 These will be connected to each of the
wires on the supplied extension as follows.
Factory TPS
Extension
(A) Black / White
(A) Black
(B) Red / White
(B) Orange
(C) Grey / Purple
(C) White
14.12 Cut Black / White wire (A) at TPS
connector on standard loom.
14.13 Strip 10mm of the outer insulation.
14.14 Slide over supplied heat shrink from Bag 8.
14.15 Solder to the Black extension wire (A).
14.16 Slide up heat shrink over soldered joint and
shrink using a heat gun. Do not use a
naked flame as heat shrink may melt.
14.17 Repeat steps 13.12-13.16 for wires (B)-(C)
according to above table.
Page - 47 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
15. Water Pump Drive Shaft
Replacement
15.1 Place drip pan under alternator cover to
catch any remaining oil.
15.2 Remove 14 cap screws securing alternator
cover.
15.3 Using 2 derby cover fasteners (3), position
alternator stator cover remover/installer
tool (HD-45304) (4) as shown.
15.4 Install two gasket alignment dowels (HD45340) (2) in two of the alternator cover
holes to steady cover as it is removed.
15.5 Remove alternator cover by pulling
outwards. Beware of fingers as the cover
is held in place by the alternator magnets.
15.6 Remove alternator cover gasket and set
aside for reuse in re-assembly stage.
NOTE: If cover removal tool and dowels not
available, cover can be removed by levering at 2
lever points on the back side of the cover.
LSAFETY WARNING: Be careful of fingers as
the cover is held in place by the alternator
magnets and may snap back into place if not
removed carefully.
Support stator housing and place to one side. Be
careful as wire harness is very short.
15.7 Holding crankshaft 36mm rotor nut with
wrench, loosen triple sprocket fastener and
remove.
Page - 48 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
15.8 Attach Sprintex® drive shaft guide, Part No
201P9001, to engine at points indicated
using 4 M6x16mm cap screws supplied
with tool. Do not tighten bolts yet.
15.9 Carefully insert Sprintex® drive shaft tool
Bag 14, Part No 201P9005, into shaft
guide, inserting tool into triple sprocket.
15.10 When aligned correctly, tighten Sprintex®
guide.
LSAFETY WARNING: Prior to using the
hammer, ensure you have reasonable footing to
avoid slipping or falling. Also ensure the bike is
well secured and will not fall over.
15.11 Gently tap drive shaft tool through triple
sprocket, pushing out water pump drive
shaft, and keeping triple sprocket in correct
position.
NOTE:
DO NOT REMOVE DRIVE SHAFT TOOL FROM
DRIVE SHAFT GUIDE. TRIPLE SPROCKET
WILL SPRING OUT OF ALIGNMENT.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
15.12 Thoroughly clean the shaft from Bag 4 with
an air drying solvent paying particular
attention to the threads in each end of the
shaft.
Apply engine assembly lube to shaft bearing
surfaces as indicated in picture.
15.13 Carefully insert replacement drive shaft
from Bag 4, through crank case.
15.14 Align shaft with alignment carrier, and
carefully tap new drive shaft through triple
sprocket, gently pushing out alignment
tool.
15.15 Care must be taken not to dislodge the
bushing behind triple sprocket whilst
tapping in the shaft.
Remove alignment tool carrier and alignment
tool.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
15.16 Using a deep 22mm socket, secure
driveshaft.
NOTE:
Do not use hex on end of drive shaft to secure
drive shaft. Damage to the shaft may occur.
15.17 Install supplied triple sprocket bolt from
Bag 4 and tighten to 77Nm (56.8ft-lb)
Note that triple sprocket bolt is left hand thread.
NOTE:
Use Loctite ® 222 or similar locking agent on
triple sprocket bolt.
After tensioning bolt tap the head of the bolt with
a soft mallet to ensure that shaft bushing is
seated correctly in the crankcase.
NOTE:
After installing driveshaft, ensure crankshaft
turns freely, and drive shaft has a minimum
0.05mm/0.002” end float. Only rotate crankshaft
in correct direction.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
MODIFICATION PROCEDURES
15.18 Using a new gasket, or using a sealant on
the old gasket, carefully align and replace
alternator cover.
LSAFETY WARNING: Be careful of trapping
fingers when replacing alternator cover. It
will snap into position due to the magnets
within the alternator body.
15.19 Fit all bolts to cover and tighten to 9.7Nm
(7.2ft-lb) according to the procedure
pictured.
15.20 Route stator wiring harness through cable
clip and latch clip.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGER KITÊ
SECTION 3
INSTALLATION INSTRUCTIONS
Page - 53 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
1. Drive Body Installation
1.1
Using supplied drive body from Bag 6,
Apply a thin smear of sealant around points
indicated.
1.2
Apply a thin smear of grease on the two orings on the drive body.
1.3
Ensure the original water pump gasket has
been removed, and that the crank case
surface is clean from debris and oil.
1.4
Apply engine lube along the length of the
shaft where the roller bearing and seal in
drive body run.
1.5
Carefully insert supplied drive body into
water pump drive housing, ensuring not to
damage O-rings.
1.6
Secure drive body to engine using Bag 6
supplied M6x16mm cap screws and Bag 1
supplied M6x35mm cap screw and the
supplied schnor washers from Bag 6.
Tighten to 10Nm (7.4ft-lb)
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
2. Supercharger Brace
Installation
2.1
Secure supercharger brace from Bag 5 to
drive body at points indicated with 4
supplied M6x16mm cap screws and schnor
washers from Bag 5. Tighten cap screws
to 10Nm (7.4ft-lb)
3. Drive Pulley Installation
3.1
Fit drive pulley from Bag 7 to drive shaft.
Use a small amount of Loctite® 680 or
similar on the mating faces between the
shaft and the pulley.
3.2
Secure drive pulley with supplied
countersunk M10x25 bolt from Bag 4, and
tighten to 52Nm (38ft-lb). Ensure to hold
pulley by using a 36mm spanner across
flats on hex centre.
3.3
Use Loctite® 222on drive pulley bolt, be
careful not to apply to countersunk face of
bolt head.
4. Cooling System Installation
4.1
Fit cooling assembly by fitting manifold to
radiator and securing with previously
removed hose clamp. Tighten clamp to 34Nm (2.2-2.9ft-lb).
4.2
Align cooling assembly with chassis upper
chassis rail and front rail.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
4.3
Attach electric water pump hose to drive
body fitting using supplied hose clamp and
tighten clamp to 3-4Nm (2.2-2.9ft-lb).
4.4
Locate radiator cap body from Bag 11 in
pictured location.
4.5
Attach ½” hose to drive body using
supplied hose clamp, Bag 11, and tighten
to 3-4Nm (2.2-2.9ft-lb).
4.6
Attach radiator cap body to water manifold
using hose clamp provided and tighten to
3-4Nm (2.2-2.9ft-lb).
4.7
Fasten previously removed P-clamp
around both coolant pipes and secure to
front rocker cover with fastener. Tighten
fastener to 6-10Nm (4.4-7.4ft-lb).
4.8
Ensure no hoses are kinked and cooling
assembly is properly located, not rubbing
on any engine or chassis components.
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INSTALLATION PROCEDURES
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
5. Battery Installation
5.1
Slide battery back into battery box ensuring
that the terminals are at the top. (Positive
on left hand side).
5.2
Connect the positive lead and fasten using
previously removed fastener.
Tighten
fastener to 6.8-10.9Nm (5-8ft-lb).
5.3
Do not connect earth lead yet.
5.4
Do not replace battery strap yet.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
6. Supplementary Engine Control Unit Installation
Figure 6-1
1. Supplementary ECU – SMT6H
2. Diagnostics Connector. To be connected
to HD diagnostics plug.
8. Supplementary
Injector
Connector.
Connected to supplementary injector on
underside of supercharger kit intake
manifold.
3. TPS Connector. To be connected to
break-out loom from TPS extension.
9. Injector Connector. Connect to front fuel
4. Earth Connector. To be connected to
battery earth on rocker cover.
10. Crank trigger output.
5. Water Pump Connector.
water pump.
Connected to
6. Supplementary MAP sensor Connector.
Connected to MAP sensor on side of
supercharger.
7. Injector Connector. Connect to front
cylinder fuel injector.
injector connector on factory loom.
11. Crank trigger input.
12. Data
interface
connector.
(no wires to be connected)
13. Air Temperature Sensor Plug
14. Computer Diagnostic Plug
15. IAC Connector. Connect to Intake Air
Sensor on Throttle Body.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
6.1
Insert supplementary ECU and loom on top
of battery as shown.
(Insert with
connectors first). Ensure wiring loom is
located back out through battery hold down
strap.
6.2
Move hold-down strap over battery and
supplementary ECU to secure into position.
6.3
Undo battery earth cable from rocker cover.
6.4
Place earth connector from supplementary
loom onto mounting bolt and refasten using
the previously removed nut.
6.5
Ensure battery earth cable is located flush
against the battery.
6.6
Remove connector from front cylinder fuel
injector.
6.7
Connect supplementary loom male injector
plug (9 in Figure 6.1) to factory front
injector connector.
6.8
Connect supplementary loom female
injector plug (7 in Figure 6.1) to front
cylinder injector. (Not connected in picture
for clarity).
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INSTALLATION PROCEDURES
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
6.9
INSTALLATION PROCEDURES
Route water pump plug under injector body
and connect to water pump.
6.10 Connect multiplug on supplementary loom
to diagnostics multiplug located at RHS of
battery.
6.11 Carefully mount connected wires to stable
mounting points using cable ties.
7. Supercharger Installation
7.1
Carefully lubricate O-rings on supplied fuel
injector, Bag 10 with rubber grease.
7.2
Insert inlet end of fuel injector
previously installed injector hat.
7.3
Connect supplementary injector connector
from installed wiring loom, (connector 8 in
figure 6.1), to injector. Align injector as
shown, with connector facing downwards.
into
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
7.4
Throttle cables need to be re-routed
through battery hold down strap, on RHS of
supplementary control unit on top of
battery.
7.5
If battery positive connector is unprotected,
use plastic conduit to protect and prevent
possible shorting.
INSTALLATION PROCEDURES
NOTE: Please make sure that all sealing
tape is removed. Remove transit cable tie
from actuator linkage as shown in picture.
7.6
Carefully place supercharger upside down
over engine in position shown.
7.7
Fitting pull cable first, insert throttle cable
barrel into swing arm as shown.
7.8
Fit outer cables to locating posts. Ensure
throttle operates correctly, without sticking,
and check to make sure full throttle can be
achieved.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
7.9
INSTALLATION PROCEDURES
Carefully rotate swing-arm clockwise, and
slip cable over swing-arm.
7.10 Whilst pulling on outer cable, slide inner
cable under throttle shaft arm, over post
and locate in slot in throttle cable post.
7.11 When located as shown release outer
cable and allow to fit snugly in counter-bore
in throttle cable post.
7.12 Fit throttle return cable barrel to swing arm.
7.13 Pull back cable outer and insert into throttle
cable post.
NOTE:
It may be necessary to wind back the throttle
cable adjustment at the grip to allow cable to
extend back to cable post.
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
Throttle Cable Adjustment
7.14 Turn the throttle adjusters, (2,4) and jamnuts (3) as short as they will go. Both
cables should have zero adjustment at the
start of this procedure.
7.15 Ensure the front wheel is pointed straight
ahead.
7.16 Turn the throttle grip wide open and hold it
there.
7.17 Turn the throttle cable adjuster (2),
lengthening the sleeve, until the throttle
cam just touches the cam stop.
7.18 Tighten the adjuster jam-nut and (3) and
release the throttle.
7.20 Check adjustment.
a. Work the throttle grip to be sure
the cable returns to idle position
when released.
7.19 Turn the idle cable adjuster (4), lengthening
the sleeve until the cable housing touches
the spring on the cable support sleeve.
LSAFETY WARNING: Check that the throttle
control operates freely without binding. Irregular
or sticking throttle response could cause a loss of
control, leading to an accident which could result
in death or serious injury.
b. If the cable does not return to idle,
turn idle adjuster, shortening the
sleeve until correct adjustment is
reached. Tighten the jam-nut (3)
NOTE: If the throttle is slow to return, ensure
that the cables are located correctly and
not twisted or bent too sharply. If the
throttle is still slow, the cables will need to
be oiled or replaced.
7.21 Carefully flip supercharger over.
7.22 Insert supplementary injector into base of
inlet manifold.
7.23 Fasten supplementary fuel injector to
supercharger manifold using two M5x20
cap screws and two schnor washers from
Bag 10. Tighten cap screws to 6Nm (4.4ftlb)
NOTE:
Ensure that fuel injector connector points
downwards as much as possible to prevent
interference with throttle linkage.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
7.24 If V-rod has early model breathers which
have been previously modified; Push front
and rear hoses over brass fittings on
plenum chamber.
7.25 If late model breather (moulded), fit the rear
cylinder breather to rear brass fitting, and
secure with cable tie.
7.26 Carefully lower supercharger assembly and
push front breather over the front cylinder
rocker cover breather tube.
7.27 Connect electrical plugs to additional MAP
sensor (1), IAC (2), TPS (3), and IAT
sensor (4).
(Supercharger kit shown
installed).
7.28 Carefully mount supplementary loom
securely to chassis rail or other stable
mounting points.
7.29 Press supercharger down into inlets.
7.30 After ensuring supercharger is located
properly, tighten inlet hose clamps to 35Nm (2.2-3.7ft-lb).
7.31 Insert air temp plug into air temp sensor
(number 13 – refer to wiring diagram page
58)
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
7.32 Connect the fuel pressure regulator pipe to
the quick fit tee supplied.
To plenum /
supercharger
To fuel pressure
regulator
To MAP
sensor
7.33 From RHS of bike, loosely fasten two
M6x20 cap screws and two M6x16 cap
screws, Bag 5, through brace and into
supercharger assembly.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
7.34 Fit supplied hardened washers and nyloc
nuts to Plenum Mount bracket studs and
tighten to 15NM.
7.35 Tighten two M6x20 and two M6x16 cap
screws on RHS of bike to 10Nm (7.4ft-lb)
7.36 Connect the negative lead to battery,
fasten using previously removed
fastener, and tighten to the 6.8-10.9Nm
(5-8ft-lb).
Page - 66 - of 82
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
8. Crank Angle Sensor
8.1
Remove L/H radiator side cover by
removing cap screw and lifting off
cover.
8.2
Route crank angle sensor plugs along
frame and cable tie.
8.3
Unplug crank angle sensor and plug in
plugs (1) and (2).
8.4
Cable tie wiring and plugs.
8.5
Replace side cover securing with
previously removed cap screw.
Page - 67 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
9. Air Filter Fitting
9.1
Remove belt tensioner from inside air filter.
9.2
Remove filter from protective cover.
9.3
Install filter to throttle body inlet.
9.4
Tighten hose clamp to 3-4Nm (2.2-3ft-lb).
10. Coolant Bottle Installation
10.1 Install supplied coolant bottle (note: the
supplied coolant bottle has an indentation
to clear the check butterfly actuator).
10.2 Fit breather pipe to top of coolant bottle (1).
10.3 Using supplied overflow hose from Model
Box connect hose to radiator cap body
overflow fitting.
10.4 Thread pipe through protective sleeve
which was removed from original overflow
pipe and pipe clamp. Install pipe onto
bottom fitting on overflow bottle and affix
pipe clamp (2).
10.5 Cable tie pipe so that it is not kinked or
rubbing on any engine or chassis
components.
Refilling Cooling System
Note: It is important to fill and bleed cooling
system with bike on side stand.
LSAFETY WARNING: Ensure coolant does not
make contact with other parts. Use a funnel and
drop cloth to prevent damage.
10.6 Remove air bleed plug from top cooling
system hose.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
10.7 Fit bleeding assembly (barb with clear riser
tube).
10.8 Through new radiator cap body and filler
neck, fill cooling system with genuine
Harley-Davidson extended life antifreeze &
coolant up to lower sealing surface in
radiator cap body until the coolant is visible
in bleed riser tube.
Page - 69 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
10.9 Replace filler cap and turn ignition to IGN.
This will activate the electric water pump
which will circulate the coolant. Whilst the
pump is running the coolant level will drop
in the riser pipe.
10.10 Switch off the ignition and carefully remove
the filler cap.
10.11 Top up coolant level if required and repeat
above steps until coolant level in both the
filler neck and riser tube no longer drops.
10.12 Once cooling system has been bled of all
air, place some tissue paper or cloth;
around the riser fitting base and remove
bleeding assembly.
10.13 Fit bleed plug with sealing washer and
tighten to 9 – 11 Nm (6.6 – 8.1 ft-lb).
Note:
It is advisable to place a cloth under the bleed
point to catch any spilt coolant. Coolant is
extremely toxic and will permanently mark any
paint it comes into contact with.
10.14 Check coolant level and add as necessary
through filler neck up to lower sealing
surface in filler neck.
10.15 Run
engine
to
normal
operating
temperature and then recheck system
coolant level repeating above steps as
needed.
10.16 Check coolant level in overflow bottle with
coolant cold and bike on side stand. Add
coolant to cold Full Line as needed.
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Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
11. Belt Tensioner Fitting
11.1 Fit supplied belt tensioner using one M8x45
cap screw and zinc washer from Bag 3 in
location shown. Ensure spring tag sits
properly in locating hole. To do this, apply
pressure in a clockwise direction to the
tensioner assembly while tightening the
mounting bolt.
11.2 Tighten cap screw to 25Nm (18.4ft-lb)
12. Belt Installation
12.1 Route supplied drive belt, Part No. 4PK945
over bottom drive pulley and over
supercharger pulley.
12.2 Using 15mm spanner rotate drive belt
tensioner clockwise until belt can be routed
as shown. The new belt will need to be
levered over belt tensioner.
12.3 Release belt tensioner ensuring belt is
correctly aligned on both drive pulleys.
Page - 71 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
13. Exhaust Refitting
13.1 Gently lift the lower muffler, auxiliary volume,
13.9 Place clamp (18) on upper muffler (25). Slide
and header pipe assembly into position.
muffler over upper opening of auxiliary volume
(24). Position clamp with compression fastener
to inboard with tightening nut upward.
13.2 Slip both front and rear header flanges over the
studs in the cylinder heads. Thread two hexnuts (4) on header flange studs. Do not tighten.
13.10 Thread upper muffler fasteners (1) into the
lower muffler (26). Do not tighten.
13.3 Reinstall oxygen sensor cable with bracket (29)
13.11 Torque the fasteners to the indicated torque in
and plug cables back into harness.
the following order.
13.4 Install support pin (11) in isolator mount (17) on
the exhaust support. Thread on the hex-nut (4).
Do not tighten.
13.5 Hold a ½” spacer between frame rail and the
header pipe exhaust clamp.
a.
Upper muffler clamp – 65Nm (48ft-lb)
b.
Upper muffler fasteners – 23Nm (17ft-lb)
c.
Lower muffler and auxiliary volume
fasteners to support bracket – 23Nm
(17ft-lb)
d.
Exhaust flange hex-nuts – 6-10Nm (4.47.4ft-lb)
13.6 Thread in the lower muffler fastener (1) through
the exhaust support.
13.7 Thread in the auxiliary volume fastener (1)
through the bracket (27) and the exhaust
support. Do not tighten.
13.8 Torque the pin hex nut to 23Nm (17ft-lb)
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
13.12 Check the tightness of the exhaust clamp
by the clamp nut to 32-37Nm (23.6-27.3ftlb).
13.13 Replace front and rear heat shields.
Tighten the heat shield screws to 10Nm
(7.4ft-lb).
13.14 If removed, replace drive sprocket cover.
Tighten to 6-10Nm (4.4-7.4ft-lb).
14. Refilling Engine Oil
14.1 Ensure previously removed drain plug is
installed and tightened to 35Nm (25.8ft/lb).
14.2 Fill crank case with engine oil
recommended by Harley Davidson.
as
15. Belt Cover Installation
15.1 Fit belt guard using the supplied M6 cap
screws and posts, Bag 15 in Model Box.
15.2 Loosely secure the cover at (1) with the
23mm post and M6x40mm cap screw.
15.3 Loosely fix the 40mm post and the
M6x55mm cap screw at 2.
15.4 Fit remaining posts at (3 & 4) with two
M6x75mm cap screws, and tighten all cap
screws to 10Nm (7.4ft-lb) to secure belt
cover.
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
16. Fuel System Reconnection
16.1 Reconnect fuel module (1).
17. Maxi-fuse Refitting
17.1 Replace maxi-fuse (3).
17.2 Replace RH side battery cover (2) and
secure using previously removed fastener
(1). Tighten to 10Nm (7.4ft-lb)
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
INSTALLATION PROCEDURES
18. ECU Reset
18.1 It is necessary to complete a reset of the
Turn Signal Module and the Security
Modules.
18.2 Turn ignition key to ON position.
18.3 Push key in and turn a further position
clockwise to ACC.
18.4 Wait 5 seconds for ECU to complete reset
operation.
Gauges will traverse full
deflection and return to zero position.
Reset is complete.
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGER KITÊ
SECTION 4
PRE TEST-DRIVE INSPECTION
Page - 76 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGING INSTRUCTIONS
TESTING PROCEDURES
1. Pre-Start Inspection
1.1
Ensure coolant is at correct level.
1.2
Ensure engine oil is at correct level.
1.3
Ensure throttle opens fully and returns to
stop completely.
LSAFETY WARNING: Ensure adequate steps
are taken to prevent injury, spillage or fire should
any of the required installation steps not have
been carried out to specification.
2. Engine Warm Up
2.1
Start engine and allow to run until engine
reaches normal operating temperature.
(Engine may take a few attempts to start
due to prior evacuation of fuel in fuel
system).
2.2
Check for oil leaks around stator cover.
2.3
Check for coolant leaks throughout cooling
system.
2.4
Check for fuel leaks from supplementary
injector and banjo fitting.
3. Air box Cover Refitting
3.1
Position air box cover so that the locating
pins on the front align with the holes on the
frame tabs above the battery and push pins
into holes.
3.2
Fasten air box cover with previously
removed bail head fastener and turn
fastener ¼ turn clockwise to secure.
3.3
Push seat down and lock into position.
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Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 003
V-ROD SUPERCHARGER KITÊ
SECTION 5
MAINTENANCE INSTRUCTIONS
Page - 78 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 002
V-ROD SUPERCHARGING INSTRUCTIONS
MAINTENANCE PROCEDURES
1. Supercharger Drive Belt
Replacement
1.1
Remove air box cover by turning retaining
fastener ¼ turn counter clockwise. Pull air
box cover away from locating holes.
1.2
Place cover in a safe place away from
potential damage.
1.3
Remove belt guard by removing 4 M6 cap
screws and mounting posts.
1.4
Using a 15mm spanner,
tensioner clockwise.
1.5
Lever belt
release.
1.6
Remove worn drive belt from top and
bottom pulley and discard.
1.7
Route new Gates drive belt, Part No.
4PK945 over bottom drive pulley and over
supercharger pulley.
1.8
Using 15mm spanner rotate drive belt
tensioner clockwise until belt can be routed
as shown. The new belt will need to be
levered over belt tensioner.
1.9
Release belt tensioner ensuring belt is
correctly aligned on both drive pulleys.
away
from
rotate
belt
tensioner
and
Page - 79 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 002
V-ROD SUPERCHARGING INSTRUCTIONS
MAINTENANCE PROCEDURES
1.10 Fit belt guard using the previously removed
M6 cap screws, posts and washers.
1.11 Loosely secure the cover at (1) with the
23mm post and M6x40mm cap screw.
1.12 Loosely fix the 40mm post and the
M6x55mm cap screw at 2.
1.13 Fit remaining posts at (3 & 4) with two
M6x75mm cap screws, and tighten all cap
screws to 10Nm (7.4ft-lb) to secure belt
cover.
1.14 Position air box cover so that the locating
pins on the front align with the holes on the
frame tabs above the battery and push pins
into holes.
1.15 Fasten air box cover with previously
removed bail head fastener and turn
fastener ¼ turn clockwise to secure.
1.16 Push seat down and lock into position.
2. Supercharger Oil Level
Inspection
2.1
Place bike on bike stand ensuring that the
supercharger kit is perfectly level.
2.2
Remove fill plug from top of supercharger
gearbox cover.
2.3
Remove level plug from
supercharger gearbox cover.
2.4
Using Redline 75W90 high quality fully
synthetic gear oil, or equivalent, add a
small amount of oil to gearbox until oil
drains through oil level plug on side of
gearbox.
side
of
NOTE:
NEVER OVERFILL GEARBOX AS DAMAGE
WILL OCCUR. ONLY EVER FILL TO LOWER
OIL PLUG LEVEL.
Page - 80 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 002
V-ROD SUPERCHARGING INSTRUCTIONS
MAINTENANCE PROCEDURES
3. Supercharger Removal
3.1
This is a reversal of the installation steps in
Section3. The necessary steps are as
follows.
7.
Undo bolt securing supercharger to
rocker cover.
8.
Undo supplementary
remove.
9.
Undo hose clamps at inlets.
10.
Undo wiring connectors at IAC, TPS,
MAP, IAT.
injector
1.
Remove air box cover.
2.
Remove maxi-fuse.
3.
Remove belt cover.
4.
Remove belt.
11.
Remove air filter.
5.
Remove belt tensioner.
12.
Remove breather hoses.
6.
Undo bolts securing supercharger to
brace.
13.
Remove throttle cables.
14.
Remove supercharger assembly.
and
4. Supercharger Oil
Replacement
4.1
With supercharger assembly removed from
the bike, remove the top and bottom
gearbox cover plugs.
4.2
Tilt supercharger to allow all oil to drain
from gearbox. Allow to drain for several
minutes.
4.3
Sit supercharger upright on a flat surface.
4.4
Using Redline 75W90 high quality fully
synthetic gear oil, or equivalent, add a
small amount of oil to gearbox until oil
drains through oil level plug on side of
gearbox (approximately 60mL).
NOTE:
NEVER OVERFILL GEARBOX AS DAMAGE
WILL OCCUR. ONLY EVER FILL TO LOWER
OIL PLUG LEVEL.
4.5
Refit oil drain plugs to gearbox and follow
instructions in Section 3 to re-install
supercharger kit.
Page - 81 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 002
V-ROD SUPERCHARGING INSTRUCTIONS
5. Spark Plug Replacement
5.1
Remove supercharger kit as described
above.
5.2
Replace spark plugs as instructed in
Section 2, Modification Instructions, subsection 3.
MAINTENANCE PROCEDURES
NOTE:
Ensure to use specified DCPR9E spark plugs
with plug gaps set to 0.62mm/.025”
5.3
Re-install supercharger kit as described in
Section 3, Installation instructions, subsections 7 to 17.
Page - 82 - of 82
Copyright ©
Harley-Davidson V-Rod ’07 – ’08
Supercharger Kit Installation Instructions
201D1005 Rev 002
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