mr.pitstop
Expert
Well I did the install. The charger was a relatively easy install with proper tools and some patients. Much easier and more straight forward than the rear mount turbo installs I have done in the past. A few spots in the instructions were a little foggy but I was able to figure out what needed to be done. Took my time and made sure every single connection was done, all wires were away from heat and sharp spots. It gets tight in the middle when you are installing the oil tank and battery with all the wiring under it all and making sure none of it is pinched or rubbing.
Heres a pic of the sled all stripped down and ready to start the install:
Another shot of the sled, ready to go:
Oil tank removed:
Cut slot in bottom side pannel for charger protrusion The camera flash makes the scratches show up, you don't see them with the naked eye and it will be mostly covered by the supplied plastic cover:
Drilling out the rivets in the front of the deltabox to install the oil tank bracket and battery tray supplied with the charger:
Installing the first part of the charger, the leg that holds the plennum box up it simply bolts to the manufacturers engine lift eyelet:
Another shot of the plennum box arm installed:
Installing the bracket that holds the cdi and keeps the oil feed hose straight and away from moving parts:
The atmospheric pressure sensor that has to be removed and relocated way up above the engine on the heldlight bracket, it has to be higher than the plennum box so no moisture travels down the tube from the plennum and into the sensor:
Heres a pic of the sled all stripped down and ready to start the install:
Another shot of the sled, ready to go:
Oil tank removed:
Cut slot in bottom side pannel for charger protrusion The camera flash makes the scratches show up, you don't see them with the naked eye and it will be mostly covered by the supplied plastic cover:
Drilling out the rivets in the front of the deltabox to install the oil tank bracket and battery tray supplied with the charger:
Installing the first part of the charger, the leg that holds the plennum box up it simply bolts to the manufacturers engine lift eyelet:
Another shot of the plennum box arm installed:
Installing the bracket that holds the cdi and keeps the oil feed hose straight and away from moving parts:
The atmospheric pressure sensor that has to be removed and relocated way up above the engine on the heldlight bracket, it has to be higher than the plennum box so no moisture travels down the tube from the plennum and into the sensor:
Hopefully I'll be doing mine next week. What gearing will you run?
mr.pitstop
Expert
The new oil lines installed on the motor and oriented in the approximate direction:
Fitting in the oil tank and trying to pull the oil drain hose down under the motor at the same time is a little challenging but can be done, took some extra time to make sure every thing fit into place and cleared all the stearing arms:
The oil drain hose sticking out from under the motor, this is how I will do oil changes from now on, not a problem as far as I can see:
The garage bench, covered with tools and crap all about during the install, I had the laptop opened up with all the info I needed in front of me:
The oil tank bolted down with all the oil lines attached:
Everythings coming together nice:
another shot:
Fitting the starter relay into place. This took some time and several attempts. I could not get it all to lay in there nicely with all the wiring wanting to go in different directions it took some unplugging and rerouting to get everything down in place so it would all clear the oil tank and battery box and starter. I had to take a break and go back to it during this process so I could get these wires to fit into place so I was happy with em, I didn't want anything rubbing or crimped or touching something hot so I took my time and made sure everything was in place before I went on.
Fitting in the oil tank and trying to pull the oil drain hose down under the motor at the same time is a little challenging but can be done, took some extra time to make sure every thing fit into place and cleared all the stearing arms:
The oil drain hose sticking out from under the motor, this is how I will do oil changes from now on, not a problem as far as I can see:
The garage bench, covered with tools and crap all about during the install, I had the laptop opened up with all the info I needed in front of me:
The oil tank bolted down with all the oil lines attached:
Everythings coming together nice:
another shot:
Fitting the starter relay into place. This took some time and several attempts. I could not get it all to lay in there nicely with all the wiring wanting to go in different directions it took some unplugging and rerouting to get everything down in place so it would all clear the oil tank and battery box and starter. I had to take a break and go back to it during this process so I could get these wires to fit into place so I was happy with em, I didn't want anything rubbing or crimped or touching something hot so I took my time and made sure everything was in place before I went on.
mr.pitstop
Expert
Fitting the battery box into place, making sure the wires are all run in the proper place and not pinched or rubbing:
fitting in the battery, I turned the battery 180 degrees and ran the cables up the outside rather than in between the box and the oil tank per G-force's recommendations:
It takes a little work but everything will fit nicely:
PTO installed through the alternator cover, I forgot to take any pics while I had the cover off but it comes off pretty easy. once all the outside allen head bolts are out, you simply pull the cover off, the magnetic pull of the flywheel pulls back, once off you have to make sure the starter gear stays in place and take out the flywheel bolt, then put the cover back on and install the PTO through the cover:
Back plate installed on the alternator cover, this is an easy bolt on
Another shot of the back plate installed, simply bolts to the alternator cover:
Dont forget to install the spacer between the back plate and the turbine, I missed it at first and had to take the turbine back off and install it. I knew something was up because the turbine was touching the back plate and I know at 10,000+ RPMs that would not work too good. I took another look in the box and found an aluminum spacer, a second look at the pics and I noticed it was installed in the pics in the directions, but it was never talked about in the text and I missed it...
Turbine installed and tightened to 60 ft lbs, now I have the proper 1/8" distance between the turbine and the back plate:
Plastic housing installed over turbine with prefilter installed, plastic housing was a little bit of a challenge but I got it where I wanted it and its on TIGHT:
Another shot of the housing installed:
Plennum box installed, everythings looking great and is lining up perfect:
All hooked up looking good:
Nothing in the instructions about this hose, Per Helmic (much respected TY member), this hose is to be turned down and left open.
Notice the yamaheater, Im ready for some riding this season:
fitting in the battery, I turned the battery 180 degrees and ran the cables up the outside rather than in between the box and the oil tank per G-force's recommendations:
It takes a little work but everything will fit nicely:
PTO installed through the alternator cover, I forgot to take any pics while I had the cover off but it comes off pretty easy. once all the outside allen head bolts are out, you simply pull the cover off, the magnetic pull of the flywheel pulls back, once off you have to make sure the starter gear stays in place and take out the flywheel bolt, then put the cover back on and install the PTO through the cover:
Back plate installed on the alternator cover, this is an easy bolt on
Another shot of the back plate installed, simply bolts to the alternator cover:
Dont forget to install the spacer between the back plate and the turbine, I missed it at first and had to take the turbine back off and install it. I knew something was up because the turbine was touching the back plate and I know at 10,000+ RPMs that would not work too good. I took another look in the box and found an aluminum spacer, a second look at the pics and I noticed it was installed in the pics in the directions, but it was never talked about in the text and I missed it...
Turbine installed and tightened to 60 ft lbs, now I have the proper 1/8" distance between the turbine and the back plate:
Plastic housing installed over turbine with prefilter installed, plastic housing was a little bit of a challenge but I got it where I wanted it and its on TIGHT:
Another shot of the housing installed:
Plennum box installed, everythings looking great and is lining up perfect:
All hooked up looking good:
Nothing in the instructions about this hose, Per Helmic (much respected TY member), this hose is to be turned down and left open.
Notice the yamaheater, Im ready for some riding this season:
mr.pitstop
Expert
Installing the barcket to relocate the parking brake calliper
Parking brake calliper installed in new location, with supplied bolts and washers.
The bolts that hold the parking brake calliper onto the bracket stick through the back of the bracket just a fraction of an inch but I'm worried it might rub a hole in my chain case so I added just one more washer to the bolts, it gives it just enough to keep the bolt inside the bracket and there is still plenty of thread to hold the calliper on.
Plastic and aluminum shield installed, they were kinda a pain to get together, the aluminum bracket had to be bent and the plastic tab stretched to make them mate together, it was also very tight getting this shield between the chain case and the charger.
Can anyone tell me why I have this rubber O ring and this small screw left over?? I reused the rubber O ring that was on the smaller plastic cap on the alternator cover, like the directions said.. Was I supposed to use this one???
I didn't like how the parking brake cable seamed like it could easily get pushed into the brake disc as I demonstrate here with my finger.
so I drilled a couple small holes and fastened the cable to the plastic shield so it would not be able to be pushed into the brake disc.
I'll be installing the clutch kit this weekend and buttoning everything up (still don't have any oil in it) and I'll follup with a few more pics and info.
Parking brake calliper installed in new location, with supplied bolts and washers.
The bolts that hold the parking brake calliper onto the bracket stick through the back of the bracket just a fraction of an inch but I'm worried it might rub a hole in my chain case so I added just one more washer to the bolts, it gives it just enough to keep the bolt inside the bracket and there is still plenty of thread to hold the calliper on.
Plastic and aluminum shield installed, they were kinda a pain to get together, the aluminum bracket had to be bent and the plastic tab stretched to make them mate together, it was also very tight getting this shield between the chain case and the charger.
Can anyone tell me why I have this rubber O ring and this small screw left over?? I reused the rubber O ring that was on the smaller plastic cap on the alternator cover, like the directions said.. Was I supposed to use this one???
I didn't like how the parking brake cable seamed like it could easily get pushed into the brake disc as I demonstrate here with my finger.
so I drilled a couple small holes and fastened the cable to the plastic shield so it would not be able to be pushed into the brake disc.
I'll be installing the clutch kit this weekend and buttoning everything up (still don't have any oil in it) and I'll follup with a few more pics and info.
Apex2006
TY 4 Stroke Guru
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Great job and nice detailed steps with pics!
let us know how well it improves the performance and worth the bucks. I am leaning towards the investment soon!
let us know how well it improves the performance and worth the bucks. I am leaning towards the investment soon!
SledFreak
TY 4 Stroke God
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Awesome writeup... Tom, this should be a sticky...
helmic
Expert
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hose
That hose,You just turn it pointing down and live it there.
mr.pitstop said:
That hose,You just turn it pointing down and live it there.
mr.pitstop
Expert
Re: hose
Ok, thats what I'll do. Thanks...
helmic said:
Ok, thats what I'll do. Thanks...
helmic
Expert
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Re: hose
It was my pleasure,I hope you have as much fun with it ,as I had.
Cheers Perry...
mr.pitstop said:
It was my pleasure,I hope you have as much fun with it ,as I had.
Cheers Perry...
unclearpine
Extreme
SledFreak said:
This is something that a lot of members would use as a reference,I know I will.Thanks Mr pitstop
mr.pitstop
Expert
unclearpine said:
No problem. It always helps for people getting ready to do their install or people who are trying to decide on the purchase to have an idea of how it goes together.
I was planning on putting on the finishing touches tonight but Im pretty tired, probably try and finish it up tomorrow.
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SledFreak said:
This should be in the Tech pages in a word doc. Then it wont get lost. As well as Yamacharger should pay for so much free press.
bobber
Extreme
The Yamacharger, Power Commander and Ignition Module I ordered is on its way. After reading this thread, the laptop will be sitting on the work bench as well.
Great write-up and pictures.
Great write-up and pictures.
mr.pitstop
Expert
MrSled said:
Not really intended to be a "how to" or an advertisement for g force, just a series of pics with descriptions for others to see. I've had fun installing this charger system, I'll be finishing it up and installing the clutch kit today or tomorrow and I'll post up some more pics and info as I go. cheers....
