Thunder Round Air Kit Install - Motorcycle-Journal Forums

**drgibson** · 05-18-2006, 12:03 PM

Well I got the Thunder Air Kit I ordered and installed it last night. Here is the play by play.

First I go over the instructions to see what tools I will need. 4mm and 5mm Allen Wrenches, 10 mm & 8 mm Sockets, Pliers, Phillips Head screwdriver, Saw

, Electrical Tape.

As I read over the instructions;
Step 1; Remove Seat – (2) 10mm bolts Why?
Step 2; Remove Dash Plaque – 1-4mm Allen – center bottom bolt only. Lift and undo Speedo and electrical plugs
Step 3; Loosen two tank mounting bolts, top and bottom – 12mm. Remove fuel line
Step 4; Lift tank from rear. Disconnect vent lines and L shaped fuel fitting from bottom of tank. Squeeze side tabs and pull to disconnect.
Step 5; Lift tank slowly and make sure you have disconnected all electrical plugs.
Ok now I’m all ready skeptical why do I need to take the tank off to remove the Air Cleaner?

I move on and read the rest of the Instructions and decide I’ll just do it and hope I’ll understand the whys as I go a long. I pass through step 5;
Step 6; Remove both chrome air cleaner covers – 5mm Allen Heads
Step 7; Remove left stock backing plates – 10mm Bolt - two Philip screws

Remove mounting bracket behind backing plate.
(Now we’re talkin’)
9) REMOVING RIGHT SIDE BACKING PLATE:
A: Use pliers to slide hose (gray hose) clamps back and pull hoses off. Hoses will remain connected to sensors. Sensors not used in new install.
B: Remove two Philips screws holding cross over tube.
C: Remove chrome 10mm bolt
D: Remove four (4) 5mm Allen head bolts and pull backing plate off using your thumb to push hose from fresh air system out.
E: Pull crank case breather hose off,
F: Disconnect electrical connector.
G: Electrical probe will screw into the new adaptor.
Step 10; Cut zip tie holding fresh air hose then pull hose off canister. Plug with red plug provided.
(Can I just skip to Step 23?)
Step 11; Vent hose that connected to left side backing plate will be hanging. This can be removed by removing side cover (left side). Then disconnect rubber strap holding emission canister and pull off top hose (with green band) then pull hose out and remove. Plug with black plug (enclosed) (California Models Only)
Step 12; Cut off flanged end of cross over tube (left side)

. Then pull out from the right side. This is a tough one. ß-- Yeah that’s an understatement Add removing the bracket that holds the Air Sensor tubes on the right side 4 bolts and encouraging it with a rubber mallet. Oh and at this point there is no going back… period.
Step 13; Install the threaded L barb to back of the new adaptor. (A parts list would have been nice and which hole do I use?)
Step 14; Install electrical probe from back into the new adaptor. (Ok again which hole do I use and why won’t it fit into any of them?) I finally found it on the side not the back and threading it was… tricky.
Step 15; Wrap sensor wire and tape. Tuck up out of sight.
Step 16; Connect crankcase breather to L barb and connect electrical plug.
Step 17; Attach new adaptor to the throttle body using 4– 6 x 10mm bolts included. (Hey it’s starting to take shape can I skip to Step 23 yet?)
Step 18; Put plugs on sensor pipes.
Step 19; Install backing plate onto new adapter (Two Flat Head 6mm)
Step 20; Install filter and cover.
Step 21; Reinstall tank and dash in reverse order. Make sure to connect all line and electrical connections. (Ok now why did I need to remove the tank? I still have NO FRIGGIN” IDEA!)
Step 22; Reinstall seat and you are ready to ride.
Step 23; START AND ENJOY THE THUNDER (All is well, well almost…)

After the install I still have an Idle Adjustment Cable without a home so I have to figure out how to remedy that.

I made the adjustments on the FI controller and I regained some of the rpms I lost and it isn’t backfiring. I’m calling the dealer today to get it dyno’d.