I recently added a Hypercharger to my 07 FXSTC and wanted to share some of my mistakes in an effort to make it easier for anyone thinking about doing the same thing. This wasn't a "difficult" mod, but it did have it's moments! The instructions state you need the service manual for you bike, "Now that was a good suggestion!", but I didn't have one, so I proceeded cautiously.

Item # 2 in the instructions says remove the gas tank. Here's where I though maybe I should go get a manual. (Obviously I'm hard headed) So I decided to just lift the tank from the rear enough to get to what I needed to get to. No major problems there, except for the plumbing underneath the tank. Underneath your left thigh is your fuel supply line, it runs from out of the back corner of the fuel tank to the fuel injection system. There is VERY little slack in this line. Withought disconnecting it, I lifted the rear only about 3 or 4 inches and the end that attaches tot he fuel injection system snapped off, just a little plastic hose adapter, and thus fuel begins to run out. I grabbed the fuel can and slung the fuel line into it, (of course I had just filled up the bike) Washed up & went to bed.

It's important to note that under your left thigh (while sitting) where the fuel line comes out of the tank, there is a chrome collar. The collar is just like a quick disconnect, If you slide it up the fuel supply line comes loose, and little or no fuel is lost other than what is alread in the line & drains back. I found that out from my new manual I just purchased!!!

Once the fuel had drained, I was ready to proceed. I lifted the rear of the tank (which was more than enough room to take care of business) and tied it up with some strong nylon cord. NOTE: Not removing the tank kept me from having to do anything with the dash to, it all stayed connected. See pic one!

Now I was able to get to it. Hyperchargers need vaccum to operate the butterflies. Prior to late summer/fall, you had to drill a hole in your intake manifold, tap it & insert a nipple for the vaccum line to fit on to. Now Kuryakyn has come out with a vaccum adapter (Thankfully!! I wasn't thrilled with the idea of medal shards anywhere near my intake manifold!)

Kuryakyn provides very good instructions for this modification, but I added a few quick photo's. See pic 2, you have to remove the 2 bolts holding on the IAC bracket. Unplug the wiring going to theIAC unit. You also have to remove the throttle cables, not to tough but you have to loosen the slack adjuster by the hand grip.

Remove the IAC unit & bracket. Now you can get to waht you need which is the MAP sensor. The MAP sensor sits in a hole in the intake manifold, if you pull it straight up you now have a premade hole. Plug the MAP sensor into the "new" adapter, then plug the adapter into the premade hole & you have vaccum access for the hypercharger.

NOTE: I talked to my service dept chief at the stealer & he wigged out that I was messing with the MAP sensor. He said, "That MAP sensor is in a certain position at a certain height for a reason". "I have seen Sportsters barely able to run, and just by pushing on the MAP sensor the smothed out & ran perfect." Now after thinking about it this probably makes sense. NOT that the MAP sensor was out of it's one & only perfect position, but that it needed pushed down to obtain the good vaccum seal it needed!! With the MOD installed, my bike runs no different than it did before. He said, "If you have any problems, bring it in & we'll tap a hole in the trottle body and add the old style adapter & leave the MAP sensor alone. How curteous of him,

 

Once the adapter is installed you can replace (folloing the directions) the MAP sensor, IAC & adapter & throttle cables. Then you can lower the tank.

Now all that's left is mounting the hypercharger itself. As before there are pretty good instructions & the only problems I had was sliding the mounting bolts through the charger, spacer & all the gaskets. A problem DID occur when screwingin the mounting bolts. The ones that come withthe charger are pretty cheesy. I do not have a torque wrench, & I didn't think I was wrenching on them TOO much, but I wound up braking the heads off of two of them. There was pleanty of them sticking out to get a pair of visegrips on to back them out & a quick trip to the stealership & I had three new(chrome) bolts. They held up a little betterIMHO. There are three bolts. (On a clock) One at 1 O'clock,One at 5 O'clock & one at 9O'clock. The one at 9 O'clock does not screw all the way through, meaning the bolt hole does not screw through to open air, as thereis a sensor behind itso on it I added a spacer to keep it from bottoming out. The other two will screwin & seat well.

I have not received my powercommander or pipes yet, but I have run the bike since thisMOD, and noticed not decrease in performance. The bike definately does NOT run funny, miss, or backfire, so I must have done something right! The Hypercharger is also slimmer than the stock aircleaner. The stock used to rest against my inner thigh when I rode, now the hypercharger does not. Better pic's when the sun comes out!

IfI can answer any questions please feel free to reply/PM me & I'll answer if I can. I'm not a wrench, but felt confident with doing this.

Keep the shiny side up!

Coolhand




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Good advice, about getting a manual, ain't no more rubber hose and clamps. $50-$60 bucks on a $17,000 bike is a good investment.

 

Yep, the fuel line fitting I snapped off ran me 40.00 bucks. I couldn't buy just the fitting, it was the whole thing. That was 40.00 bucks towards the manual, which I bought anyway to save the money later. I tells how to disconnect the fuel line to keep from breaking it like I did....

 

Here is a few sunny shots:



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Looks great, like the Tri-bar tailight.