#150-19-1000
| 2016-2018 YAMAHA YXZ1000R SUPERCHARGER SYSTEM
INSTRUCTIONS
INSTRUCTIONS
The Kraftwerks Supercharger kit for the ’16-’18 Yamaha YXZ1000R was designed for easy installation. Competent mechanics with the appropriate tools will find the process to be relatively simple. This is a GENERAL installation guide; the installation and vehicle may vary slightly and some parts may not reflect current production pieces.
PLEASE BE AWARE THAT SOME PARTS MAY COME PRE-ASSEMBLED BUT ARE NOT TORQUED TO SPEC.
Review the installations in its entirety before beginning the installation. If you have any questions about your ability to perform the installation, take your vehicle to a qualified installer. If you cannot find an installer, please contact the seller or Kraftwerks directly for a referral.
If you will be using a floor jack, be sure to have properly rated jack stands to safely keep the vehicle in the air while it is being worked on. NEVER WORK UNDER A VEHICLE WITHOUT APPROPRIATE JACK STANDS.
INTRODUCTION
• Engine Rev Limiter must be set below 10,500 RPM. Any higher RPM will OVER-SPIN the Rotrex Supercharger head and WILL void its warranty.
• Kraftwerks Supercharger Kits do not require break-in or warm-up periods. However, always warm your engine up properly before operating at full boost.
• If an engine oil and filter change has not been performed recently, do so now using a high quality oil and filter. • A minimum of 91 OCTANE fuel must be used.
• Fuel Filters with more than 50,000 miles of use must be replaced prior to operating engine under boost (this is critical to proper fuel flow and engine performance).
• Vehicles with more than 100,000 miles of use, consider installing a new radiator and thermostat (coolant / water with high calcium content can leave deposits over time that can inhibit proper cooling.
DISCLAIMER
• Only use genuine Rotrex SX150 Traction Oil for supercharger lubrication. The proprietary traction formula protects the supercharger where other oils would fail, and is what allows its high-RPM operating levels. Use of Non-Genuine Rotrex SX150 Traction Oil WILL void the warranty of the Rotrex Supercharger.
SUPPORT PARTS
» The Kraftwerks Quick Release LED Buggy Whip is the best way to make sure you’re seen in style!
Package Includes:
- 17" x 18" Orange Kraftwerks Safety Flag - 4’ 9" Fiber-Optic Whip Pole
- Anodized Billet Aluminum Quick Release Pole Base - 3" Anodized Billet Aluminum LED Quick Release Mount - 120" Quick Release Wire Harness
- 1-1/2" Bolt, Nut, Washer, and Lock Washer
KRAFTWERKS QUICK RELEASE LED BUGGY WHIP
GRAMS PERFORMANCE 550 CC FUEL INJECTORS
» Grams Performance is proud to offer the most innovative high-performance fuel injectors for today’s high-performance vehicles. Premium materials, advanced manufacturing techniques, and stringent quality control procedures make Grams Performance the leader in high-performance fuel injectors.ITEM NO. PART NUMBER DESCRIPTION QTY. 1 C032-0242-06 REV C SC BRACKET, YAMAHA YXZ SC KIT 1 2 C032-0241-06 REV A SIDE COVER, YAMAHA YXZ SC KIT 1 3 C032-0243-06 REV A BELT COVER, YAMAHA YXZ SC KIT 1 4 C022-0094-08 REV B GASKET, SIDE CASE, YAMAHA YXZ SC KIT 1 5 C022-0095-08 REV B GASKET, SC PLATE, YAMAHA YXZ SC KIT 1 6 C022-0096-03 REV A GASKET, BELT COVER, YXZ SC KIT 1 7 C025-0020-03 DOWEL PIN, 6.0 OD X 10MM LENGTH 2 8 C2AC-0600-25 AHCS M6X1.00X25 1 9 C2AC-0600-30 SCREW, AHCS, M6 X 1.0 X 30 7 10 C050-0019-00 REV NC OIL SEAL, YAMAHA YXZ SC KIT 1 11 C014-0159-12 REV NC ADAPTER, CRANK PULLEY, YAMAHA YXZ SC KIT 1 12 C002-0194-05 REV NC CRANK BOLT, YAMAHA YXZ SC KIT 1 13 C2AC-0600-12 AHCS, M6 X 1.0 X 12MM 6 14 C2SS-0825-10 SET SCREW, HEX SOCKET, FLAT TIP, M8 X 1.25 2
23 30 4 2 5 1 9 10 11 29 6 3 24 13 19 27 26 17 18 16 15 22 25 12 21 20 28 7 14
COMPONENT DIAGRAMS
» Tools/Materials Required for Installation: - Metric Wrench Set
- Screw Driver Set - Metric Socket Set - Dremel Tool - Drill Bit Set - Drill
- Hole Cutter Set - Hose Cutter - Plier Set - Torque Wrench - Red Threadlocker - Blue Threadlocker - Silicone Sealant - Scraper Tool - Quick Snip Tool - Impact Driver
PRE-INSTALLATION
1
» Disconnect the Battery Ground/ Negative Cable and drain the motor oil from the Dry Sump Tank.
DRAIN OIL DRY SUMP
2
» Drain the Oil from the Engine.
DRAIN ENGINE OIL
3
» Remove the side panels, and the rear cargo bed.
REMOVE PANELS AND CARGO BED
4
» Remove the Header.
HEADER REMOVAL
5
» Remove the Dry Sump Assembly and Lines but retain the OEM Spring Clamps for use later in the installation process.
OIL DRY SUMP AND LINES
6
» Remove the Brake Caliper and remove all the bolts from the Brake Rotor.
BRAKE COMPONENTS REMOVAL
7
» Remove the Breather Assembly.
BREATHER ASSEMBLY REMOVAL
8
» Remove the Air Intake Box
AIR INTAKE BOX
9
» Remove the Engine Side Cover. Remove the QTY 3 Allen Bolts retaining the Stator. Remove the Stator Assembly itself.
SIDE COVER REMOVAL
10
» Locate the Supercharger Main Bracket Assembly (pictured upper left). Install the Factory Stator Components to the Kraftwerks Crank Case drive plate as shown.
Re-use and Red Loctite the Qty 3 Factory Allen Bolts and torque to 9 ft lbs.
STATOR COMPONENTS
11
» Install the OEM Factory Suction Tube with O-Ring and mount it to the Kraftwerks Crank Case. Re-use and Red Loctite the Qty 1 Allen Bolt and torque to 9 ft lbs.
SUCTION TUBE INSTALL
12
» Remove the Crank Shaft Bolt and Washer (May need to use an Impact Gun to remove).
CRANK SHAFT BOLT REMOVAL
13
» Remove/ scrape-off any excess Gasket Material remaining from the Factory OEM Gasket. Install the new Crank Case Gasket as shown (Gasket may differ from picture).
CRANK CASE GASKET INSTALL
14
» To avoid any oil leaks, Add Silicone to the Stator Harness that exits the Crank Case Cover to ensure that there are no fluid leaks.
SILICONE STATOR HARNESS
15
» Install the new Supercharger Drive Bracket Assembly (assembly is heavy and may require two people) by re-installing the QTY 12 factory M8 Bolts with Red Loctite and torquing them down to 9 ft/lbs. You will be able to access and tighten some of the bolts through the Access Holes pictured by the arrows.
Once the factory M8 Bolts have been properly torqued down, you will need to locate the provided M8 Set Screws (pictured in the upper right). Add Red Loctite to the threads and install them into the Access Holes making sure that they sit LOWER than the plate itself.
CRANK CASE COVER DRIVE PLATE
16
» Remove the stock washer from the crank bolt, clean and then add silicone to both sides (this is to avoid any oil leakage). Install on the provided Crank Bolt.
SILICONE NEW CRANK BOLT
17
» Install the new bolt to the Crank Pulley Adapter as shown and then add Red Loctite to the threads.
CRANK PULLEY ADAPTER
18
» Install the Hub Adapter and torque the new bolt to 90ft lbs.
HUB ADAPTER
19
» Remove the Air Box Lid and the air filters from the air box.
AIR BOX PARTS REMOVAL
20
» Make a mark 1-7/8" from the Air Filter Lid as shown.
MEASURE/MARK AIR FILTER LID
21
» Drill a ¾" hole as shown based on the marking from the prior step.
DRILL HOLE IN AIR FILTER LID
22
» Locate the Barb Fitting and Nut as shown here.
BARB FITTING AND NUT
23
» Add Blue Loctite and install into the Air Box Lid.
INSTALL BARB FITTING AND NUT
24
» Remove the factory rubber gasket from the Factory OEM Air Box Lid.
SIDE COVER RUBBER GASKET
25
» Install the rubber gasket from the prior step into the new Rotrex Airbox Lid as shown.
INSTALL RUBBER GASKET
26
» Heavily silicone the INLET side of the secondary air filter as shown.
SILICONE AIR FILTER ASSEMBLY
27
» Install the secondary air filter back into the Air Box. Heavily silicone the OUTLET side of the secondary air fiter.
SILICONE OUTLET SIDE
28
» Heavily silicone the new Kraftwerks side cover, hand tighten all screws
SILICONE KRAFTWERKS SIDE COVER
29
» Install the Plug onto the Port (highlighted with the arrow) and secure with a Worm Gear Clamp as shown.
PLUG AIR BOX
30
» Install the ECU management. The YXZ1000R Kit was tuned using the DynoJet Power Commander V (Please refer to the Power Commander V Instructions for installation).
ECU INSTALLATION
31
» Install the supplied T-Fitting and attach the Vacuum line for the Blow-Off Valve as shown.
BLOW-OFF VALVE VACUUM LINE
32
» Remove the factory smog pump plates, hoses and solenoid.
SMOG PUMP REMOVAL
33
» Install the Kraftwerks Block-Off Plate and Red Loctite the bolts. Torque to 8ft lbs.
BLOCK-OFF PLATE INSTALL
34
» Install the Kraftwerks Air Box Assembly. If not already pre-installed, install the provided Barbed Fitting as highlighted by the Arrow.
KRAFTWERKS AIR BOX ASSEMBLY
35
» Install the Intake Air Temperature (IAT) Sensor.
IAT CLIP INSTALL
36
» Install the Idle Air Control Valve (IACV) Tube as shown.and secure with provided Worm Gear Clamp.
IACV VALVE TUBE
37
» Install the Oil Separator and Bracket.
OIL SEPARATOR BRACKET
38
» Cut and modify the OEM Oil Separator Tube with the provided Union Barb Connector and attach the other end to the Barbed Fitting mentioned in Step# 35.
UNION BARB CONNECTOR
39
» Install the new Kraftwerks Breather Hoses marked (Trim to fit as needed).
BREATHER HOSE SET INSTALL
40
» Re-Install the Dry Sump Tank but DO NOT tighten the bolts at this time.
DRY SUMP OIL TANK
41
» Install the new Kraftwerks Oil Hoses (these are different than the BREATHER Hose in Step #40) and secure with the OEM Spring Clamps removed from Step #6.
DRY SUMP TANK OIL HOSES
42
» The Rotrex Head Unit and Pulley should come pre-installed but be sure to double-check all of the mounting bolts to make sure that none are loose.
ROTREX S/C HEAD UNIT
43
» Install the Lower Pulley onto the Pulley Adapter and Red Loctite the M6 bolts. Torque to 8ft lbs.
LOWER DRIVE PULLEY
44
» Prepare to install the Belt by adjusting the Tensioner Pulley Assembly to the Full Upward position as shown.
IDLER PULLIES
45
» Install and route the Supercharger Belt as shown. Loosely install the Static Tensioner Assembly (do not tighten bolt at this time).
S/C BELT / TENSIONER
46
» Download the “Gates Carbon Belt” App for your smartphone. This App will be used to measure the viibration and tension of the belt.
Open the App and place the Smartphone Microphone next to the longest section of the belt. Flick the belt and it will give a HZ reading.
Tighten the Adjustment bolt until the belt tension is between 140-145 Hz. Once the proper tension has been set, torque the Tensioner Bolt to 15ft lbs and tighten the 10mm nut to lock the setting in place.
TENSIONER ADJUSTMENT
47
» Install the Belt Cover Plate and Gasket using the supplied M6 Allen Bolts. Blue Loctite the bolts and torque to 8ft lbs.
BELT COVER PLATE
48
» Re-install the factory Brake Rotor. Torque bolts to 10ft lbs.
RE-INSTALL BRAKE ROTOR
49
» Re-install the factory Brake Caliper. Torque bolts to 25ft lbs.
RE-INSTALL BRAKE CALIPER
50
» Using the supplied Template, drill 3 holes in the Rear Cargo Cover using Hole Saw sizes 2-½" ,1 ¼", and 3".
DRILL HOLES IN CARGO COVER
51
» Install the Kraftwerks Charge Pipe Plate. Install the Qty 6 Allen Bolts as shown and tighten to 10ft lbs.
CHARGE PIPE PLATE INSTALL
52
» Remove the Qty 3 bolts holding the Dry Sump Tank and let it rest on the tire.
REMOVE DRY SUMP OIL TANK
53
» Re-install the rear cargo cover.
RE-INSTALL CARGO COVER
54
» Install the Dry Sump Tank Cover and torque the bolts to 8ft lbs.
DRY SUMP TANK COVER
55
» Locate the Rotrex Oil Filter Clamps and 5/16" hose. Cut one 10" and one 15" piece of the hose.
Connect the 10" length to the hose INLET of the oil filter.
Connect the 15" length to the OUTLET of the oil filter. Install clamps and banjos and the end of the hoses.
ROTREX OIL FILTER ASSEMBLY
56
» These are mounting locations for the Rotrex Oil Filter Assembly and the Rotrex Oil Reservoir:
ROTREX OIL RESERVOIR/FILTER
57
» Install the Oil Filter Assembly onto the frame as shown using the supplied P-Clamp and hardware.
OIL FILTER ASSEMBLY INSTALL
58
» Locate the Rotrex Oil Reservoir Assembly.
ROTREX OIL RESERVOIR ASSEMBLY
59
» Install the Rotrex Oil Reservoir Assembly as shown (NOTE: Production Model may differ from what is pictured).
ROTREX OIL RESERVOIR INSTALL
60
» Install the 10" Oil Hose to the bottom of the Rotrex Oil Reservoir as shown (NOTE: Place the Spring Clamp on the Hose FIRST). Make sure that the Fittings are tightened down.
10" OIL RESERVOIR HOSE
61
» Install the 15" hose to the INLET of the Rotrex.
Make sure that the Fittings on the Rotrex Supercharger Head Unit are tightened down.
15" OIL FILTER HOSE
62
» Locate the Intercooler Assembly and Mounting Brackets. Mount Brackets to the Roll Cage a shown on BOTH sides and then
INTERCOOLER MOUNTS
63
» Mount the Intercooler to the Brackets. Center the Intercooler as shown.
Once the Intercooler has been centered, tighten down the bolts.
MOUNT INTERCOOLER
64
» Locate the Rotrex Oil Cooler Assembly and install the Qty 2 54" 5/16" Oil Hose Lengths onto each Fitting.
Secure with provided 5/16” Spring Clamps (slide clamps on hose first for ease of installation).
ROTREX OIL COOLER ASSEMBLY
65
» Place the Oil Cooler Assembly onto the back side of the Intercooler with the Fittings upwards as shown and then use the included Mounting Ties to attach the Oil Cooler Assembly to the Intercooler.
MOUNT ROTREX OIL COOLER
66
» Run the Oil Cooler Lines towards the passenger side and Zip-Tie them together as shown.
OIL COOLER LINES
67
» Install one of the Oil Cooler Lines to the INLET (Top) of the Rotrex Oil Reservoir as shown (NOTE: Place the Spring Clamp on the Hose FIRST).
Make sure that the Fittings are tightened down.
ROTREX OIL RESERVOIR INLET LINE
68
» Install the other Oil Cooler Line to the “OIL OUT” fitting of the Rotrex Supercharger Head Unit as shown (NOTE: Place the Spring Clamp on the Hose FIRST).
ROTREX S/C OUTLET OIL LINE
69
» Re-Install the header.
RE-INSTALL HEADER
70
» Locate the Blow-Off Valve Silicone Hose Assembly as shown.
BLOW-OFF VALVE HOSE ASSEMBLY
71
» FIRST, connect the Vacuum Hose from Step #32 to the Vacuum Port on TOP of the Blow-Off Valve and secure with a Zip-Tie. Next, install the Cold Side Hose using the provided Lined Hose Clamps.
COLD SIDE HOSE INSTALL
72
» Locate the Rotrex INLET Silicone Hose as shown..
ROTREX S/C INLET HOSE
73
» Install the Rotrex INLET Silicone Hose by attaching it to BOTH the Rotrex Supercharger Head Unit and New Intake Air Box (NOTE: Place the Lined Hose Clamps on the Silicone Hose PRIOR to installion).
ROTREX S/C INLET HOSE INSTALL
74
» Locate the HOT Side Silicone Hose as shown.
ROTREX S/C OUTLET HOSE
75
» Install the HOT Side Silicone Hose as shown (NOTE: Place the Lined Hose Clamps on the Silicone Hose PRIOR to installation).
ROTREX S/C HOT SIDE HOSE INSTALL
76
» Connect the Breather Hose from Step #40 to the BACK of the Center Tube.
BREATHER HOSE
77
» Refill the Fluids starting with the Motor Oil Fluid ensuring BOTH the engine and Dry Sump are full.
Make sure that there is nothing near the INLET and OUTLET Charge
PRE-START UP CHECK
78
» Fill the Rotrex Fluid so that it shows the “Maximum” Level on the Dipstick (NOTE: Rotrex Fluid Level must be checked when the Dipstick on the Rotrex Oil Reservoir is FULLY twisted on).
FILL ROTREX OIL RESERVOIR
79
» Loosen the “OIL IN” Bolt at the Rotrex Head Unit but do not remove fitting.
Using a LOW PRESSURE (+/- 30 psi) Air Pump, use a Rag and Air Nozzle to push air through the Rorex Oil Line until you see Rotrex Traction Fluid bleeding through the fitting you just loosened. Once you see Rotrex Traction Oil. tighten the Banjo Bolt back down. Re-Fill the Rotrex Oil Reservoir as needed until the Fluid is at the Maximum Level.
Priming the Rotrex Head Unit is vital to ensure that the Rotrex Supercharger itself does not run dry on initial start-up.
PRIME ROTREX OIL LINE
80
» Once the fluids have been check, remove the Dipstick from the Rotrex Oil Reservoir (so someone can check the level). Ensure that the Tuning Map has been loaded in the Power Commander V and Start Engine and
INITIAL START-UP
81
» Locate the Cargo Cover.
Using a Dremel or other cut-out tool, cut a hole for the Rotrex Oil Lines on the UPPER section of the Cargo Cover as shown.
CARGO COVER MODIFICATION
82
» Install the Upper Cargo Cover as shown.
UPPER CARGO COVER INSTALL
83
» Locate the 2.5" COLD Side Intercooler Charge Pipe Assembly. Install it between the RIGHT side Intercooler Inlet and RIGHT side Larger Port on the Kraftwerks Plate as shown.
COLD SIDE INTERCOOLER PIPE
84
» Locate the 2.0" HOT Side Intercooler Charge Pipe Assembly. Install it between the LEFT side Intercooler Outlet and LEFT side Smaller Port on the Kraftwerks Plate as shown.
HOT SIDE INTERCOOLER PIPE
85
» Locate the Breather and Install it on the Center Port of the Kraftwerks Plate as shown.
BREATHER
86
» Check all Fluids, Charge Pipe Connections, and Hose Lines. Start-up the engine and let it idle for 5 minutes checking all fluids and
FINAL START-UP
87
Kraftwerks USA offers a 12 MONTH Limited Warranty against defects in materials, components, and workmanship unless specified otherwise. The warranty period starts on the ORIGINAL date of retail purchase directly from Kraftwerks or from your local dealer (Warranty of the Rotrex Supercharger Head Unit is also ONE YEAR from original purchase date). This limited warranty is only offered to the ORIGINAL OWNER (receipt will be required for verification). Furthermore, the warranty excludes any electronic components manufactured by other companies. IF THE KRAFTWERKS SUPERCHARGER KIT IS ALTERED FROM THE FACTORY SETTINGS, THE WARRANTY MAY BE VOID.
This includes but is not limited to the following:
• Over spinning of the Rotrex supercharger head unit • Use of non-approved or custom hubs/pulleys
• Alteration of brackets, pulleys, and other drive components
• Modification or re-routing of any charge piping or intake system that is included in the “FULL” Kits
Kraftwerks will honor a warranty claim at its sole discretion after the component in question is inspected at the Kraftwerks facility and/or the Rotrex A/S facility located in Denmark. NO WARRANTY CLAIM WILL BE ACCEPTED IF THE COMPONENT IS FOUND TO HAVE BEEN TAMPERED, MISINSTALLED, MISUSED, OR MISHANDLED (I.E. DROPPED) IN ANY WAY. Furthermore, disassembly of the Rotrex Supercharger Head Unit voids ALL warranty claims. No Kraftwerks dealer is authorized to make any warranty claims, repair, or modification. Any claims for freight/shipping damages will need to be directed towards the freight/shipping company.
• -If the component in question is covered under the Kraftwerks USA limited warranty, the product will be repaired or replaced at the discretion of Kraftwerks USA.
• -If the component in question is not covered by the Kraftwerks USA limited warranty, our Kraftwerks staff will advise you on the specific reason, the cost of replacement/repair, and the estimated time it will take.
TO PROCEED WITH A WARRANTY CLAIM
Contact KraftwerksUSA directly at (951) 808-9888 and be prepared to send the following information to [email protected] 1. Copy of original receipt or invoice. Please note that PayPal payment verification alone is not accepted
2. Pictures and description of issue. Please limit 1-2 pictures per email or compress images 3. Contact information: Name, address, and phone number
4. Vehicle description: Year, make, model, and any additional/supporting modifications
Once all of the above have been received and the warranty claim has been INITIALLY approved by Kraftwerks USA; you will be contacted with a Return Merchandise Authorization (RMA) number. You will then be directed to package the component(s) in question, write the RMA number (in BOLD) on the outside of the box, and a call tag will be issued to pick up the package from your location. Kraftwerks USA is located in California. Please be aware that warranty claims will be shipping GROUND (faster shipping available at an additional cost to you) so please allow enough lead time for shipping and inspection of the component(s). Please package components securely as any damage to components due to improper packaging will NOT be covered by the limited warranty. Please note that if a Rotrex supercharger head unit is being sent in for warranty inspection, the lead time will be longer due all head unit warranty inspections are handled by Rotrex in Denmark. Only Rotrex can approve or deny head unit warranty claims (if this is a time sensitive case, we do offer CORE CHARGE options. Please contact a KraftwerksUSA representative for more information).
Please note that KRAFTWERKS USA is NOT liable for the voiding of your factory warranty nor any damage(s) to clutch, transmission,
