READ BEFORE STARTING.
Before starting, you will need to purchase a new set of throttle and return cables 4 to 6 inches
longer than your current cables, the TC Ram Charger is 6 inches longer than your stock OEM manifold ,
the TC Ram Charger is NOT DESIGNED FOR USE WITH CRUISE CONTROL. Also we would highly recommend a
service manual for more detailed information regarding removing and installing the Induction Module
Assembly in the fuel injection section of the manual.
1. DISCONNECT THE BATTERY GROUND CABLE, disconnecting the battery ground cable will PREVENT serious
damage to ECM (electronic control module).
2. Remove the air cleaner cover, air filter and backing plate
3. Disconnect the idle air control, throttle position sensor and intake air temperature sensor.
4. Remove the throttle body from the intake manifold, (using the supplied T20 power bit) unscrew
the two T20 screws that hold the throttle body to the manifold access to the top screw can be
found by (remove the horn if it is in the way) placing the power bit between the manifold and the
fuel rail. ( Fig. A)
5. Remove the intake air temperature sensor from the throttle body and install the supplied cover
and gasket. ( Fig. B)
6. Reinstall the intake air temperature sensor in the TC ram charger flange, with the sensor facing
the engine torque screws to 12 INCH lbs. ( Fig. C)
7. Remove and replace throttle and return cables (cables need to be 4 to 6 inches longer than current length).
8. Securely snug down the manifold absolute pressure sensor by wrapping the wire tie around the
manifold and hooking the sensor so that it cannot fall off, clip off extra wire tie (Fig D).
9. MAKE ABSOLUTELY SURE that your battery ground cable is disconnected.
10. The throttle position sensor connector and the idle air control connector need to be
lengthened , on the clip side of the connectors, molded into the connector are the letters A
B C (throttle position sensor) and A B C D (idle air control), cut off the factory connectors
leaving 1/8 to ¼ inch of wire left on for reference, (so that you know by looking, that the A
wire for example is a light green wire with a dark green tracer and B wire has a different color
ect. in this step we are adding a new connector to your existing wiring harness, so place the
shrink tube on the wire first and strip (approximately ¼ inch) and solder A wire on the harness
to A wire on the connector and heat up the shrink tubing around the soldered joint and do the
same to B wire and C wire Ect. Until both connectors are soldered onto the factory harness. (Fig. E)
11. Place an O ring on the intake manifold side TC Ram Charger flange, a dab of grease will
keep the O ring in place, using two M4 x 20 mm screws apply some loctite, bolt the TC Ram
Charger to the intake manifold and torque the screws to 27 to 33 INCH lbs
12. Bolt the TC ram Charger to the engine using the banjo bolts and washers, the banjo bolt
with the nipple goes on the front cylinder and torque both bolts 120 to144 INCH lbs
13. Attach throttle and return cable to the throttle body.
14. Place an O ring on the throttle body flange and again apply a few dabs of grease to the O
ring to hold it in place and using two M4 x 20 mm screws apply some loctite bolt the throttle
body to the TC Ram Charger and torque the screws to 27 to 33 INCH lbs.
15. Adjust throttle and return cables. CHECK FOR BINDING.
16. Place the brass screen between the throttle body and the ram stack, using the ¼
20 x ¾" cap screws bolt down and torque the screws 20 to 40 INCH lbs, NOTE: the brass
screen can be removed for maximum performance, however even if the screen is used, the bikes
computer MUST still be reprogrammed to compensate. (Fig. F)
17. Remove the rubber vacuum cap covering the steel tube between the idle air control and
the throttle position sensor. Then plug in the vacuum line into the steel tube and the banjo
bolt with the nipple on the front cylinder.
18. Route and connect the throttle position sensor and idle air control connectors (ROUTE THEM
AWAY from the THROTTLE and RETURN cables).
19. Install and tighten air filter.
20. Connect battery ground cable
21. Enjoy
Any questions about this kit can be answered by calling, writing or E mailing our tech line is
available 9 to 5 Central Standard Time Monday thru Friday.
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