April 29, 2010

D&D and Zippers Set 2010 Dressers Free

Simple Performance Mod with a Big Bang
By Bandit and the Departure Bike Works Crew

Here's our test subject, a 2010 dresser belonging to a Departure Bike Works Customer.

We keep up on exhaust systems. The damn things are forced to change as fast as new models are released. D&D runs dyno tests on every exhaust system they make, plus they have developed new, better flowing touring bike mufflers, so when they completed a 2010 two-into-one system, we had to find a bike quick.

One of our Bonneville bikes, the 1940 45 flathead, with a K-model top end is being built in Richmond, Virginia, at Departure Bike Works. Lee Clemens and his team have a full service shop. They were featured in Biker Build-offs, in the S&S 50th build, and have a long history at the drag strip.

First thing, they rolled this big puppy onto their Dyno Jet, for a base line number. This shop's long-standing career spans almost 40 years. So D&D shipped the: 2010 - Harley FLH / FLT Bagger 556-31/32 - BOSS Fat Cat 2 into 1 - Black & Chrome 2010 Harley-Davidson FLH / FLT Bagger motorcycles: D&D 2 into 1 Boss Fat Cat Exhaust pipe.

Here are the pipe options:
- Black Pipes
* 556-31B - With back cut tip
* 556-31L - With slant cut tip

- Chrome Pipes
* 556-32B - With back cut tip
* 556-32L - With slant cut tip

Note:
(Slant cut works with the CVO Extended bag models)

As you can see the system comes with all the heat shields already in place. It also comes with fasteners and new exhaust mesh gaskets. This shot also depicts the Zipper's MaxFlow air filter and backing plate (#117-448B for throttle by wire models).

In order for any biker owner to grab the absolute most out of this minor modification, there's another ingredient to this performance recipe. Increase your performance by adding a Zipper's HiFlow Air Cleaner. The D&D exhaust system with a Zipper's air cleaner is the biggest bang for your buck. Note: Zipper's air cleaner requires an additional investment.

Any 2010 owner will be bowled over by the difference these inexpensive upgrades afford a 96 or 101-inch stock twin cam engine configuration. As you can imagine stock bikes are severely restricted, and even a 96-inch Twin Cam, which should tear up any asphalt, is lackluster on the showroom floor. But this minor mod opens that performance puppy on both ends, intake and exhaust.

NO TUNER The team at D&D spent hours on the dyno testing the combination of a high-performance air cleaner with the BOSS Fat Cat pipe to ensure no tuner download is needed. With just a wrench and a ratchet, every 2010 bagger owner can be up and running within an hour. That saves time and money.

At idle, the motorbike is deep, boomy and full of character. Not only does the pipe look good, it is a wonderfully sounding experience for the rider.

BAFFLE OPTIONS
- Stock Engine - Concentric baffle
- Modified Engine - Big bore baffle

Instructions The Departure Bike team took care of the installation, specifically, Ernie Coates. Here's the drill:

1. Remove saddlebags.

This is a safety precaution. Remove the fuse and electrical issues can't occur.

2. Remove main power fuse from left side.

This move just clears the way for the whole operation and prevents scratching chrome or powdered black heat shields.
3. Remove right side floorboard.

4. Disconnect O2 sensor plugs (Under right side cover)

There's that bare monster, waiting for a performance opening.

5. Remove stock exhaust system (Retain stock transmission mount and hardware).

It's always a good idea to replace the Brillo Pad mesh gaskets for a guaranteed seal.

These O2 sensors are placed in a different location than earlier models, plus they are smaller. No using pre 2010 model pipes.

6. Remove factory O2 sensors from stock header. (Note the location of the sensors. Grey plug goes in the front pipe, Black in the rear pipe.)

7. Open box and inspect all system components (No warranty for cosmetics after pipe has been installed). Install new exhaust gaskets (They are a tight fit and need to be worked in slowly).

8. Apply a small amount of Anti-Seize to the threads of the factory O2 sensors (Be careful not to get any on the end of the sensor) and install sensors in the new header.

Ernie carefully install the new Brillo pad gaskets.

He installed the header and made sure he could route the 02 sensor leads back to the plugs.

Looks like he's chewing on the passenger peg, while trying to guide the fastener into the transmission mount.

9. Install header on motorcycle. The mount tab on the pipe goes on top of the transmission mount.

10. Loosely install factory mounting hardware. Install muffler with supplied hardware.

Ernie started with the headers and worked his way toward the stern.

11.Tighten hardware (To factory specifications) starting at the heads and working to the rear of the bike (Make sure the mount at the transmission does not bind). Check alignment as you go.

12. Reconnect O2 sensors.

At any minute Mr. Departure, Lee Clemens, might mosey into the shop and inspect the action. He's a prick, and even worse now that he was recently indoctrinated into the horrible Hamsters organization. But his wife, Brenda is cool. She smiles all the time, even when he's around. Amazing.

Installing floorboard is much easier on the new touring frames. It was a bear on the older frames.
13. Install right side floorboard.

14. Clean entire system with glass cleaner to remove any oil and fingerprints.

15. Install main fuse.

16. Install right side cover and saddlebags.

Ernie got started on the Zipper's install immediately.

17. Install a Zippers Max-Flow air cleaner according to manufactures instructions

18. Start motorcycle and check for leaks.

Zipper's MAXFLOW and HIGHFLOW Air Cleaners For Twin Cam Engines

To Make More Power, you must have more airflow! Increasing airflow at the inlet is step one - even for a stock engine. Zipper's MaxFlow and HighFlow air cleaners include high quality 100-percent washable, pleated filter elements made from multiple layers of surgical-quality cotton gauze material that traps the smallest dirt particles while providing dramatic flow increases. USA-made cast backing plates incorporate internal breather passages and are available in three finishes to match your engine and budget (standard silver aluminum cast, texture black or chrome).

All accept the standard TC "football" air cleaner cover (not included). These kits are designed to be used on Twin Cam engines equipped with the standard Twin Cam football air cleaner cover, which makes 360 degrees contact between the cover back and the rubber gasket on the filter. Do not install decorative cover inserts (due to increased weight) or use 2006-up CVO Touring model covers that do not make 360 degrees contact between the cover back and the rubber gasket.

Two filter depths are offered, standard MaxFlow and HighFlow:

Complete HighFlow Air Filter Kits

These kits are similar to the MaxFlow air filter kits except the filter is the standard 2-1/4-inch deep. This filter kit increases flow without increasing the overall width of the air cleaner for those with leg room concerns. Fits fuel injected and carbureted Twin Cam engines equipped with the factory TC88 "football" cover. Available with standard aluminum cast, black or chrome plated backing plate.

Here's the throttle body with the stock air cleaner removed. HiFlow keeps the outer cover at the same location as stock.

MaxFlow version moves the cover out approximately 3/4" wider due to the extra deep MaxFlow filter element.
HiFlow is recommended for stock engines; the MaxFlow filter should be used on modified engines with high flow exhaust systems for best results. All required mounting hardware and instructions included.

Add one of our optional billet end covers for radical looks and performance!

Zipper's Factory Note:

These kits are designed to be used on Twin Cam engines equipped with the standard Twin Cam "football" air cleaner cover, which makes 360-degree contact between the cover back and the rubber gasket on the filter. Do not install decorative cover inserts (due to increased weight) or use 2006-up CVO Touring model covers that do not make 360-degree contact between the cover back and the rubber gasket.

Ernie had to free the air cleaner element from the vent lines.

1. Remove existing air cleaner assembly, including backplate and black support bracket. Retain factory supplied cover and mounting screw (bracket is not re-used).

2. Place new gasket onto backplate, aligning holes and mounting studs.



3. Install (2) o-rings into counter bores on backplate where backplate meets cylinder head (a dab of grease will hold them in place during installation). Place backplate over throttle body with gasket in place. Apply low strength thread locker such as blue Loctite to stanchion studs and loosely attach backplate to throttle body or carburetor (do not tighten yet).

4. Install (2) o-rings over supplied breather/support bolts into recessed area under the bolt heads. Apply low strength threadlocker such as blue Loctite to support bolt threads; install bolts through backplate into cylinder heads. Tighten support bolts to 120-140 in/lbs (13.5-16.0 Nm). Tighten (3) stanchions through backplate into throttle body and tighten to 85-90 inch pounds in a sequence.

Due to the thickness of the backplate gasket, perform several rounds of the tightening as the gasket will crush and relax the torque on the stanchions. 3-4 tightening rounds should be performed to ensure proper torque.

5. Apply low strength threadlocker such as blue Loctite to (3) Torx head screws provided and install filter element to stanchions.

6. Re-install the air cleaner cover bolt through the cover. Dab a small amount of silicone seal to one side of the supplied thick washer. From inside the cover, place the supplied washer over the bolt, silicone side towards air filter element. Apply Loctite on the threads of the bolt and install the cover assembly onto the air filter element.

Tips For Cleaning Your Max Flow Filter Element

Gently shake off and brush away excess dirt. Spray on Cleaning Solution so that the filter is fully saturated, and let soak for 10 minutes. Rinse filter from the clean side to the dirty side until water comes through clear. Use only low pressure from a tap or hose.

Check these dyno results. Note first the results of the pre-mod results. They are jagged, indicating an erratic power curve, which impacts that rear wheel. This simple installation smoothed out the curve and added immediate, useable power and torque. Both D&D and Zippers have exhaust and intake kits for all Twin Cams, from '99 up. Allow filter to dry. A fan may be used to speed process. DO NOT use heated air blowers, compressed air, or open flame. Make one careful application of Filter Oil to each filter pleat. Allow oil to seep into filter for 20 minutes. Re-oil any areas that still appear dry. Do not over oil.

Expert installation of this product is available at Zipper's facility in Elkridge, Maryland. Transportation of your motorcycle to and from Zipper's can be arranged if desired. Please call a sales representative for details.

End Covers for ThunderMax MaxFlow Filters

Want that radical open element look for your MaxFlow or HighFlow filter? Install one of these chrome-plated billet beauties for striking looks and maximum flow.

Part No. Description
#172-780 5-1/2" round open air filter cover, chrome smooth
#172-781 5-1/2" round open air filter cover, chrome scalloped

Zipper's Ordering info:
To order, call 410-379-0909
Orders received by 5pm E.S.T. ship same day!

Britney from 5-Ball Racing Team approves of this tech.



April 29, 2010 10:03 PM | send page