BoonDocker Nitrous System Installation Instructions Honda TRX 450R

Transcription

BoonDocker Nitrous System Installation Instructions
Honda TRX 450R
Before you begin, please read the instructions below and check kit contents
Nitrous Kit Contents:
1 – Nitrous Manifold with 90 degree PTC fitting
1 – Nitrous Bottle with valve installed
1 – 1/8 NPT x 4AN fitting for bottle
1 – 4AN female cap for bottle
1 – Bottle Bracket (2 piece)
1 – Bottle Clamp w/wing nuts
1 – High pressure braided hose (4 feet)
1 – 12” length of 1/8” black nylon hose
1 – Solenoid
3 – Solenoid holding brackets
1 – 1/8” NPT x 1/8” OD PTC fitting for solenoid
1 – 1/8” NPT to 4AN adapter for solenoid
1 – Water Manometer
1 – Pushbutton switch
2 – Velcro and zip ties for mounting pushbutton switch
1 – Rectifier
5 – ¼” x 1” mounting bolts with washers for Nitrous Manifold
9 – misc. electrical connectors (2 male, 6 female, 1 round
terminal
2 – Orifice cup plug for 3/16” tubing
2 – Orifice cup plug for 1/8” tubing
1 – 3/16” barbed Tee
1 – 3’ length of 3/16” clear tubing
10 – Zip ties
1 – Nitrous filter (Installed on solenoid)
Tools Required:
Drill + bits (3/4”, 5/16”, 3/16)
Wire stripper / crimper tool
Side cutters
5/32”and 7/32” Allen wrench
Basic wrench and socket set
Flat blade screwdriver
Theory of Operation:
A common misconception about nitrous oxide is that it is explosive or flammable. Nitrous by itself does not burn, nor is it
explosive. At 565 deg. F, nitrous oxide (N20) breaks apart and forms two parts nitrogen and one part oxygen. Inside an
engine, this added oxygen speeds up the combustion process (the nitrogen plays an important part in buffering the
reaction). Whenever nitrous is used, additional fuel is necessary; otherwise the added oxygen will act as a blowtorch inside
your engine. When used properly, nitrous oxide provides the same benefits as turbo charging or supercharging your engine
(extra power is made by burning more fuel and oxygen), but without the added cost or complexities.
Below is a diagram of the major components of the Boondocker Liquid Nitrous System. The simplicity of this system makes it the most
reliable, easy to tune, and easy to install nitrous system available. By using the existing fuel system (carburetor) to add the required extra
fuel for nitrous, the complexity and unreliability of extra components is eliminated.
The part that makes the Boondocker nitrous system so unique is our patent pending Nitrous Manifold. This manifold
simply mounts on the airbox or air filter where it sprays a fine mist of nitrous that is then drawn into the engine through the
carburetor(s). This allows the nitrous to be naturally aspirated into the cylinder instead of being forced, which is much
friendlier to the motor and allows the nitrous to be used in a much wider range of throttle and rpm settings.
(Continued on next page)
BoonDocker Liquid Nitrous – 1589 Hollipark Dr. Idaho Falls, ID 83401 – (208) 542-4411
Website: www.boondockers.com - email: info@boondockers.com
Revised 10-29-03
Page 1 of 11
This nitrous manifold greatly simplifies the way extra fuel is delivered that is needed for nitrous use. The carburetor vents
are connected to this manifold, allowing the carburetor(s) to breathe normally through the airbox when nitrous is not used.
When nitrous is sprayed, the manifold produces a positive pressure that goes to the carburetor float bowl, which “pushes”
more fuel through the main jet of the carburetor(s). This eliminates the need for an extra fuel pump, fuel solenoid, extra
plumbing, and nozzle(s) that are necessary to inject the extra fuel in other systems.
This manifold is also designed to vary the float bowl pressure in relation to nitrous pressure, thus keeping the nitrous and
fuel delivery in sync. Fluctuations in bottle temperature greatly affect nitrous pressure, which affects nitrous delivery. By
automatically adjusting the fuel delivery as nitrous pressure varies, this manifold makes nitrous safe, reliable, and easy to
use.
Part I – Bottle Installation
Bottle fitting installation
The valve shown in picture (A) will require both the 4an x 1/8 npt fitting and the 1/8 npt plug. The valve shown in
picture (B) will only need the 4an x 1/8 npt fitting. Use thread sealant on these fittings, be sure not to get any sealant
inside the valve.
Revised 08-19-03
Page 2 of 11
1. Remove the upper mounting bolts on the front
bumper. Install bracket support strap and reinstall the
mounting bolts.
2. Install rear strap mounts over frame tubes.
3. Attach saddle bracket to support brackets, front and
rear using supplied hardware.
Bottle Filling /Weights
Automotive speed shops that sell nitrous kits can usually refill nitrous bottles. This bottle can be filled with non-medical
grade nitrous oxide that contains a very small amount of sulfur dioxide (combines with water in your lungs and forms
sulfuric acid if breathed too much). This is the same nitrous that is used for all nitrous oxide systems, usually with the
name “Ny-trous+”.
Will rupture the blow-off disk fill the bottle according to the weights below? We do not recommend overfilling the bottle
– when the bottle gets hot, it.
Note: all weights are in fractions of
pounds, not ounces
Bottle Size
2.5 lb AL Bottle
2.9 lb CF Bottle
4.0 lb CF Bottle
Weight of Cylinder & Gas
6.3 lb
6.0 lb
7.8 lb
Weight of Cylinder Empty
3.8 lb
3.1 lb
3.8 lb
Weight of Gas
2.5 lb
2.9 lb
4.0 lb
Revised 08-19-03
Page 3 of 11
Part II – Manifold installation
1.
2.
Remove seat.
Remove air box.
a. Remove the two bolts on the right side.
b. Remove the one bolt on the left side.
c. Loosen the clamp where the air box boot clamps on the carburetor.
d. Lift up air box and remove crank case breather from right side. It is a ¾ inch hose
pushed into the air box.
e. Remove air box from ATV.
3.
Grind off the ridges on the air box boot so the manifold will mount flush against the boot.
Drill a ¾ inch hole in carburetor boot install manifold and make a mark for the ¼ inch
hole. Remove manifold and drill ¼ inch hole. Insert manifold stem inside of the boot and
install manifold body on outside of the boot. Insert bolt and carefully thread through the
manifold body and into stem. Be sure not to cross thread the bolt, it will plug up the bolt.
Manifold Cutout Template
Revised 08-19-03
Page 4 of 11
Part III Carburetor Vent line installation
1.
Install tee in existing line.
2.
Replace other line with a piece of tubing that is long enough to connect to the tee with out
kinking.
3.
Then run a line off the third side of the tee over to the barbed fitting on the manifold. Be
sure and connect the vent line from the carburetor to the fitting on the same side as the push
connect fitting for the nitrous line.
4.
Find the lowest point in the line that you just ran between the manifold and carburetor.
Insert a tee and run a short line down from the tee, approximately two inches in length and
install an orifice cup lug in the end of the short line. This will allow any fuel to drain that
gets trapped in the line.
Revised 08-19-03
Page 5 of 11
Part IV Solenoid Installation
1.
Remove rear plastic (optional)
a. Remove the two bolts under each rear fender
b. Remove the two bolts that are on top of the fender where the seat rests
c. The front of the fender has two rubber grommets, one on each side and also a rubber
grommet that holds the front of the fender together.
2.
Unbolt voltage regulator
3.
Install clamp on nitrous solenoid and position behind regulator and attach using front bolt
of regulator.
4. Run nitrous line from solenoid, up along the frame rail. Route through the front plastic and
down along the frame and attach to nitrous bottle. Attach using supplied zip ties.
Revised 08-19-03
Page 6 of 11
Part V Electrical installation
1.
Remove plastic front fenders.
A. Remove two bolts on each side of the front plastic. Top two attach to the fuel
tank, lower two attach to frame rail below fuel tank
B. Remove upper panel from front plastic. There are two rubber grommets next to
the handlebars on the main plastic that the upper panel attaches to.
C. Remove the two black push connectors that hold the plastic onto the headlight
mount.
2. Attach rectifier to headlight mount using supplied hardware as shown.
3. Attach a short ground wire to one of the AC sides of the rectifier, it doesn’t matter which
one. Then attach it to the bolt shown.
4. Cut the red wire and attach an electrical connector to each end. Insert jumper and attach
to one wire coming from the nitrous button. Then attach the other wire coming from the
nitrous button to the other unused AC side of the rectifier.
5. Next run the wires from the solenoid and attach one to the + side of the rectifier and one
to the – side of the rectifier. Note: It does not matter which wire on the solenoid attaches
to the + or – side of the rectifier, you are simply completing a circuit.
Revised 08-19-03
Page 7 of 11
Rectifier markings on the side
12V
power
AC
Handlebar
switch
Ground wire
_
+
Rectifier
AC
Solenoid
Note: + and –
connections can
be wired either
way
Revised 08-19-03
Page 8 of 11
Part VI- Push Button Installation
The Nitrous button can be fastened using zip ties, or the
provided Velcro.
To install the nitrous push button using the Velcro, both
surfaces must be clean, dry and above 68 degrees F. You
can also use super glue if necessary.
To mount the nitrous button on the handle bar, find a
position that suits you and zip tie as shown in picture.(
You may need to move the controls over to make room
for the nitrous button)
Revised 08-19-03
Page 9 of 11
Part VII – Tuning Instructions
A. Carb Jetting:
Because the nitrous manifold changes the carb venting from atmosphere to inside the airbox, the main jet size may need to be
increased. When a large volume of air flows through the airbox, a negative pressure may develop inside depending on how
restrictive the airbox is. This negative pressure can cause the engine to run too lean unless the main jet size is increased.
Make sure the carb jetting is correct before proceeding with the tuning instructions.
Note: A quick check may be performed as follows:
1. With the nitrous manifold installed, run the ATV and note performance.
2. Temporarily disconnect one of the vent lines from the manifold so the carburetors are vented back to atmosphere.
3. Run the ATV again and note if performance improves.
4. If performance has improved, you will need to increase the main jet size. Increase the main jet size; reconnect the
vent line to the nitrous manifold and retest. Continue increasing the main jet size until performance is the same as
when the vent was disconnected from the nitrous manifold.
B. Important Notes before using Nitrous:
1.
High-octane fuel is strongly recommended. We have found that race fuel or race fuel concentrate mixed with
premium gas can provide the necessary octane.
2.
We also recommend using one size colder spark plug (higher number = colder). In some cases decreasing the spark
plug gap to around .020” achieves best results.
3.
Be sure to use filtered nitrous – always use a filter when filling your bottle! Debris can quickly plug the small blue
filter that is behind the brass compression fitting on the nitrous manifold.
C. Startup & Leak Test Procedure
The rider must do the following steps every time the bottle is turned on and before doing the fuel adjustment procedure.
1. With the engine off, open the bottle valve and check for leaks. Shut the bottle valve off. With the valve shut, the hose
will still have pressure in it.
2. With pressure in the hose and the bottle valve closed, start the engine. Check to make sure the solenoid does not
discharge hose pressure.
3. With the engine running (be ready to shut down engine if necessary), open the bottle valve. Push the nitrous button for
about one second or less. Engine rpm should increase if the nitrous system is functioning properly.
D. Nitrous Manifold Fuel Adjustment Procedure
The steps below should be done with a full nitrous bottle that is at the
proper operating temperature (70-90deg F). Make sure the engine is at
normal operating temperature. Do not exceed 2 seconds of nitrous use
until the fuel adjustment is complete and correct.
An experienced tuner should only perform this adjustment process. If you
are not an experienced tuner, find someone who is. Remember, safety
first!
Warning: Only adjust the fuel mixture screws according to the steps
below. The factory setting is fully closed. Begin by turning the
adjustment screw out one full turns.
Revised 08-19-03
Page 10 of 11
1. Run the vehicle in an open area at full throttle and apply nitrous for 1 or 2 seconds. Note engine power and rpms when
the button is pushed.
2. Enrichen the mixture by turning the nitrous manifold adjustment screw in (clockwise) 1/2 turn. Run nitrous for 1 or 2
seconds again and note power and rpm difference. If no power loss is noted, repeat step 2 until a loss is noted. A power
loss indicates you are rich enough (be sure!) - go to step 3.
3. To find where the mixture starts to become too lean, turn the nitrous manifold adjustment screw out (counterclockwise)
1/2 turn and note power. A power increase should be noted. Turn nitrous manifold adjustment out 1/2 turn and compare
to previous run. If no power increase is noted, go to step 4. If power increase is noted, repeat step 3 until no power
increase is noted. Use extreme caution - you can go too lean!
4. For the final setting, turn the nitrous manifold adjustment screw back in (clockwise) 1/2 turn.
5. After this adjustment is made, if the engine does not run perfectly smooth when using nitrous, do not use it! If the exhaust
note does not sound clean, the cause is likely detonation, which can quickly destroy the engine. Either use higher-octane
fuel or reduce the engine’s compression before using nitrous again.
Part VIII – Warranty, Terms & Conditions
Returned Goods – No merchandise will be accepted without prior approval. A RMA number (Return Merchandise
Authorization) provided by Boondocker is required before a return will be accepted. A 20% handling and restocking charge
will be applied to returned merchandise. No unauthorized returns will be accepted.
Limited Warranty – Boondocker warrants its product to the original purchaser against workmanship defects for a period of
90 days, commencing from the date of product delivery to the Consumer.
Maximum Liability – The maximum liability of Boondocker in connection with this warranty shall not under any
circumstances exceed the price of the product claimed to be defective.
Revised 08-19-03
Page 11 of 11

BoonDocker Nitrous System Installation Instructions Honda TRX 450R

Transcription

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