Harley-Davidson Turbo System

Overview

FEATURES

  • 53 Series Aerocharger
  • Billet Aluminum Airbox
  • Ceramic Exhaust
  • Silicone Charge Tube
  • Custom Air Filter
  • Air/Air Intercooler

Aerocharger Harley-Davidson Turbo System

Aerocharger has a legendary history with Harley-Davidson motorcycles.

From 1994 to 2001, the best selling turbo for Harley-Davidson motorcycles was the Aerocharger. Harley riders loved the Aerocharger’s cutting-edge technology, simple install and lag-free variable vane power. The system was massively popular among riders that needed more horsepower from their EVO engines, and Harley-Davidson motorcycles with Aerochargers numbered in the thousands.

Harley took notice, and an effort was made to partner with Aerocharger as the officially selected turbo for a factory turbo motorcycle. It was known as the Diablo Project.

“…Harley was unable to forge a supplier agreement with Aerocharger, and an in-house effort to develop it’s own turbo cost millions…but never produced a working product.” -CYCLE WORLD | MAY 2010

As an aftermarket turbo system, it was back to the drawing board. And now, after taking an appropriate amount of time off, Aerocharger is back. We’re returning to our Harley-Davidson roots with the release of this turbo kit, featuring the powerful 53 Series Aerocharger turbo for modern EFI Big Twin Engines.

Aerocharger Turbo Systems: the turbo with full H-D pedigree.

 

ABOUT AEROCHARGER

Aerocharger Turbo Systems is a 3rd generation engineering company and the manufacturer of the Aerocharger, a specialized Variable Vane Turbo. Aerocharger also researches and develops turbo systems for military, UTV, snowmobile, motorcycle and automotive applications. Aerocharger’s engineers have expert technical backgrounds in fuel management and thermal dynamics, and Aerocharger systems are carefully designed to prioritize efficiency, power and response.

Gallery

Aerocharged 2015 Harley-Davidson Road Glide 103″


System Specs

Compatibility

This turbo kit is compatible with all 2008+ Harley-Davidson FL-Series touring motorcycles.

Performance Gains

At stock, a 2011 Harley-Davidson FLHX 103 dyno’d at 69 hp and 86 ft·lbf torque. After installing the Aerocharger turbo system, and with a completely stock engine running 91 octane pump fuel at 8 psi boost, the same Street Glide registered 125 hp and 139 ft·lbf torque on the dyno. Real world results will vary depending on elevation, fueling and other mods and accessories.

Power Band

The Aerocharger is a unique Variable Vane turbocharger that allows boost response to be set mechanically. Unlike conventional turbos, the Aerocharger can create boost without any turbo lag, which makes power exceptionally smooth and available on demand. A smooth power band means there aren’t any dangerous surges or jolts when control is critical.

Torque

The Aerocharger system is the best system for motorcycle ridability, whether out on the salt flats or climbing up long mountain highway passes. Peak power is made around 4500 RPM, but peak torque comes on at 2000 RPM. Low-end grunt in traffic is critical for Harley riders, and the Aerocharger is famed for it’s tractor-pull power. Huge low-end torque makes it the ideal turbo for merging on highways, getting around slow traffic on steep grades, or rapidly getting up to speed from a dead stop at traffic lights.

Fueling

The Aerocharger system has been designed to run on standard 91+ Octane pump fuel. Higher octane fuels can be used for better performance, and are recommended when the system is set for high boost.

The Aerocharger 53 Series is an extremely efficient turbo under normal cruising conditions. Gas mileage can be affected depending on boost setting and riding style.

Boost Levels

Boost level is mechanically set by a pre-loaded spring inside the Aerocharger’s integrated boost controller.

The 53 Series Aerocharger ships pre-set for 5 PSI boost, with an 8 PSI upgrade spring also included. The Aerocharger’s bearings are exceptionally efficient and allow more horsepower to be produced per pound of boost than conventional turbos.

Engine Mods

The Aerocharger system is compatible with most engine mods, such as built engines and upgraded cams. High compression pistons will require higher octane fuels. If your engine is modified from stock, call an Aerocharger tech to verify compatibility.

Operating Volume

The Aerocharger system includes a muffler assembly, which is similar to typical Harley exhaust systems in noise and exhaust note. A distinct turbo Blow Off Valve “whoosh” sound will also be audible.

Reliability And Support

Many turbo’d Harley-Davidsons run Aerochargers, and riders often report getting 100,000+ miles from their original Aerocharger systems. The Aerocharger system has been heavily tested and the fuel control is solid and predictable. Aerocharger’s R&D FLHX 103 has 12,000 turbo miles on it, with only normal maintenance and on an otherwise stock bike.

The Aerocharger 53 Series has been OEM and Military tested, and is rated at over 30,000 hours. Aerochargers do not require any more care or maintenance than any other turbocharger, and a properly installed Aerocharger system should outlast the life of your vehicle. We will make sure you have the support you need – for any questions, troubleshooting or maintenance, don’t hesitate to directly contact Aerocharger’s engineers or your nearest Aerocharger dealer.

Installation

No permanent modification to the motorcycle is required, and the system can be uninstalled from the vehicle to return it to stock. The Aerocharger Harley-Davidson system can be installed at home by someone with limited space and normal garage tools. Some Aerocharger customers prefer to have their turbo system installed at a dealership or performance shop – dealers report preferring Aerocharger technology because the systems are properly designed, simplify or eliminate many fail-prone components, and require much less support and maintenance.

Contact Aerocharger for information about dealers in your area.

Orders & Shipping

Contact Aerocharger by email or phone to order this system. Aerocharger ships internationally – contact us to receive a freight quote for national and international shipping.


Components

AEROCHARGER H-D SYSTEM

Aerocharger 53 Series

VATN Technology

Aerocharger’s powerful variable geometry tech optimizes turbine size, producing lag-free boost. Excellent performance for rapid acceleration and high altitude. The ideal turbo for motorcycle applications.

Independent Oil Supply

The Aerocharger contains its own oil supply allowing for clean and fast installation, with reduced risk of complications when riding. This turbo does not require oil lines to be run from the engine, weakening the stock oiling system. It is only necessary to check the oil annually and top off as needed.

Non-Flooded Bearings

An innovative oil misting system allows for drag free bearing performance and ultra-fast spooling. A substantial performance increase over conventional ball-bearing turbochargers.

Stealthy Fitment

Sits out of the way for improved efficiency and streamlined looks. Temperature levels are comfortable for passengers, and the mounting location is compatible with common passenger foot boards or pegs.

Air Box

Durably Built

Robust design allows for best pressurization and smoothest air flow from the turbo. Finished with ceramic coating.

Turbo Optimized

Correctly shaped to provide optimal air volume to the Aerocharged Harley-Davidson V-Twin engine.

Customizable Badge

Inset Airbox plate provides real estate for custom graphics or club logos.

Intercooler

Charge Temp Drop

The Air-to-Air intercooler upgrade creates a consistent charge-temp drop for improved horsepower.

Stealthy appearance

Installs conveniently out of the way for a low-profile look. Protected by a durable ram-air scoop. Compatible with passenger foot boards or pegs.

Properly Sized

Designed specifically for the Aerocharger, for best possible system efficiency.

Stainless Exhaust

TIG Welded

Durable construction. Finished with ceramic coating.

Volume Levels

The turbo will absorb a little noise from the exhaust, but the sound of the blow-off valve more than makes up for it.

Header Pipes

TIG Welded

Durable construction by skilled production welders.

Also Included

har_NiChargeTube

Charge Tube

Durable Silicone w. custom BOV.

har_MountHardware

Exhaust Hardware

Exhaust Mounting Collar and Hardware

har_wireharness

Wiring Harness

All required wiring harnesses and speed connectors are included.

Upgrades

Injectors – $105 each

Larger injectors are required for increased fuel delivery under boost.

rzr_injectors

Power Commander V Fuel Controller – $399 ($499 with injectors)

Need a fuel controller? Everyone’s got their favorite, but we have several options that will get you on the road in a hurry. Call for information.

Power Commander 5 for Aerocharger Harley Davidson Turbo

Intercooler Upgrade – $600.00

Upgrades a non-intercooled Aerocharger Harley-Davidson Turbo Kit with an Air/Air intercooler. Contains everything necessary for a complete conversion.

Header Heat Shields(2) – $50.00

Two small heat shields. Attaches to header.

har_PipeHeatShield

Innovate Air/Fuel Ratio Gauge Option- $199.00

High-quality innovate AFR gauge features a color display for easy reference. Includes bracket and handlebar mounts

AFR Gauge for a Can-Am Maverick Turbo

Boost Gauge Option – $100.00

Aerocharger boost gauge allows you to monitor your boost level. Includes bracket and handlebar mounts

har_boostguage

Videos

Installation Video Guide

This comprehensive video guide will walk you through the install progress. To make your install easier, this video is titled and numbered to correspond with the official Aerocharger installation manual for this system. Feel free to follow along and refer to this video as needed.

Video based on the Aerocharger Harley Manual Version 1.0 – refer to the most recent manual release for any updates and changes.


Downloads

Install Manuals and Guides

 

Cycle World – Demise of the Buell Motorcycle Company

An in-depth look at the forces that brought down America’s sportbike maker. Includes mention of Aerocharger’s involvement in the project. Cycle World. Steve Anderson, May 2010