1. Remove seat.
2. Remove dash plaque. (1) 4mm allen bolt located at the bottom of the dash.
Unplug all electrical connections.
3. Remove tank mounting bolts, (top and bottom of tank). Disconnect fuel
line.
4. Lift rear of tank. Disconnect fuel line from under side of tank. Squeezing
sides and pulling to release fuel line.
5. Lift tank off of bike frame making sure all electrical connectors are
free.
6. Remove left and right air cleaner covers from side of bike (5mm allen
bolts).
7. Remove left side air cleaner backing plate.
8. Remove mounting bracket behind left side backing plate.
Remove right side backing plate marking ISC solenoids white wire for
correct reinstallation. ISC solenoids may be removed or reinstalled, this
is your option. If removed you will need to use manual choke during warm
up. Reinstallation of the solenoids can be done by using the stock hangers
from the air box and drilling the ISC hangers stock holes out to a larger
size. Then mounting the solenoids on the stock horn bracket and routing
wiring and hoses up under tank. All hardware is included in kit for
both applications (use fuel filter supplied to filter air in ISC units
if reinstalled.
9. Removal of cross over tube. After removal of the ISC units and the
temp sensor, remove screws attaching cross over tube to backing plate.
10. Removing cross over tube, cut tube with dye grinder and tin snips,
cutting tube enough to pull it out from between heads.
11. Remove ISC hoses from under throttle body unit. These hoses are metal
and rubber.
12. Remove stock reed valve covers and hoses and assembly. Install coasters.
13. Plug vacuum lines or reconnect ISC units.
14. UN-tape wiring harness to the ISC units, if you are going to relocate
them, for extra length needed to relocate ISC solenoids.
15. California models only: Remove charcoal canister in left hand side
cover. Remove fuel separator, plugging line with red marking on rear of
gas tank. The line with the blue marking is now being used as rank vent
(leave blue marked line open). Plug line from separator to intake.
16. Install temp sensor into baking plate of new adapter. Also install
crank case vent into back of baking plate. Cut to length.
17. Install new backing plate to throttle body intake using gasket and
(2) small allen bolts supplied. Use the (2) larger bolts to align backing
plate for top plate installation. Note install all four bolts before tightening
two center bolts.
18. Remove temporary alignment bolts from backing plate. Install top plate
adapter system using (2) long and (1) short allen head bolts firmly.
19. Install gasket and air box to the (3) mounting bolts in the face of
adapter. Depending on style of air box you may have to remove the cover
plate from the air box to do this.
20. After installing air box, air filter (if applicable), and cover. Reinstall
gas tank, dash and wiring. Start engine and let warm up. Set idle to 950
to 1000 RPM’s.
Enjoy Your Performance Increase.
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