800 Hypercharger Update
 
Well here's some background.  Many of us have been trying 
with great difficulty to get our 800s running well with a 
KuryAkyn Hypercharger installed.  There have been many 
posts regarding the proper jetting of the carb for this 
modification.  I've come pretty close to perfection on my 
carb jetting, so I thought I should share my experiences 
for those that are still working on this problem.

I started out with a 162 main jet that was shipped with the
Hypercharger.  This jet made the bike too lean.  I tried 
EVERY needle setting with the 162 and several idle mixture 
screw settings and the bike still ran too lean.  As a test, 
I would run the bike with the butterflies fully open and 
then manually close them with my left hand. When the 
butterflies were wide open the bike would be stuttering and
spitting.  When I closed them the bike would surge with 
power and run great.  This told me for sure that the bike 
was jetted too lean.  I taped the butterflies shut and ran 
it this way for about 1,000 miles without problems.
 
I then went to a 172 main jet and tried the 2nd and 3rd 
needle positions with the idle mixture screw turned out 3 
turns.  The bike ran very good up to 70 mph.  Above 70 mph 
the bike seemed to stutter and miss. Closing the butterflies 
did not help.  I assumed that the bike was A LITTLE rich.  
The plugs were a nice tan color, so I knew I was close. Overall 
the bike ran good and I put on about 800 miles with this setup.
It was better than the 162 because I at least could run with 
the butterflies open, but it would not work for highway 
cruising.
 
I just recently got a 170 main jet from Steve (thanks!) and 
installed it last night.  I've ridden the bike about 30 miles 
this way, but will be putting another 500 miles + on it 
Thursday and Friday on a business trip to Chicago.  Overall 
the performance with the 170 is dramatically different.  
Performance is extremely good, almost near perfect.  Low rpm
cruising and acceleration are very smooth.  I ran it up to 
100 mph last night and it still had more left.  Most of all, 
there doesn't appear to be any stuttering, missing or popping 
at any speed, the engine just runs VERY SMOOOOOTH.  My only 
problem is that the bike seems a very little bit sluggish, 
but I haven't started messing with the needle or idle mixture 
screw yet.  Also I'm running my pipes baffled right now and I
feel that the bike gets a little sluggish when baffled.  So, 
I will also try running unbaffled to see if this helps.

So my current/near perfect setup is:

Main jet - Factory 170
Needle - Dynojet #106
Needle position - e-clip 3 positions from top, no washers underneath
Idle mixture screw - 3 turns out
Pipes - V&H Straightshots currently baffled
Elevation - approximately 700 ft above sea level

I will give a brief report after my extended run with this 
setup and let you folks know how she did.  I hope that this 
helps some of you that are still working on this mod.  I know 
I haven't put enough miles on to really prove this setup out, 
but my initial gut feel is that I'm right on top of where my 
carb needs to be jetted.  Unfortunately, the Hypercharger is a 
very sensitive beast, so your required jetting may differ 
from mine.

Cap'n Kirk
kbristol@harman.com
VROC#928
VN800 Classic bone stock.................NOT!