Installing the Bandit Performance Kit from D&D and Zippers

1. Remove stock exhaust system from motorcycle. On bikes with floor boards the right front floor board will need to be removed to provide clearance for removal of the stock system and installation of our system.

2. On FLH/FLT models retain the stock crossover bracket that is attached to the starter as this piece will be required if installing one of our Ghost Pipes.

3. FLH/FLT: The stock transmission exhaust mount will need to be removed, and our bracket installed into its place. This will require the removal of the small transmission cover to gain access to the bolt located behind the clutch cable. You will require a new gasket and trans fluid for this. Available through your dealer. Some newer models do not require the cover to be removed. Failure to use the supplied bracket will cause fitment and adjustment problems.

4. All Models: Install new exhaust gaskets (included with boarzilla systems) then the head pipes with heat shields installed then reinstall the exhaust flange nuts but leave loose for now.

5. FLH/FLT: The A spacer may be required to fill the gap between the header pipe tab and the transmission mount. Once the muffler is installed you will be able to check this.

6. Install muffler onto the motorcycle and install hardware needed but leave loose. Insure everything is lined up and not hitting anywhere. The FLH/FLT systems may require the two small black spacers to line the muffler up with the header.

7. To complete the installation, start at the muffler and tighten the system toward the heads. Muffler clamp torque is 150 inch pounds. (12.5 Ft Lbs) Reinstall the right floor board with the two bolts and spacers to give the required clearance required.

8. If you are not using the O2 sensors, remove the O2 sensor plugs clean off the antisieze and locktight the O2 sensor plugs in place.

Note: This exhaust system is designed to be used with baffles intact and unmodified. If you do not have the experience to install the system yourself. Have a dealer install the system for you.

Note: There is no warranty on exhaust pipes and mufflers with regard to any discoloration. Blueing is caused by tuning characteristics, cam timing, carburetor jetting, over heating, etc. and is not caused by defective manufacturing.

Gene recommends that the header bolt are the first to be installed followed by the tranny bracket and the muffler loose. D&D supplies spacers for the muffler to insure it's aligned with the system and for the floor board to make sure is clears and doesn't damage the new pipe.

Once the D&D system was completely in place we started tightening the headers first then worked our way back until the system was tight and ready to rock.

Then we turned to the EFI system and the Air Cleaner. As it turned out the supplied system was virtually the same as my Screamin' Eagle set-up. We replace the used filter with a fresh one and moved on.

The Zippers Thundermax Auto Tune Module, coupled with the ThunderMax EFI Module would have been an installation breeze of removing the stock EFI system, unplugging it and replacing it with the Zippers unit, but nooo. The Terry component system called for wiring and splicing wires which had to be eliminated.

Here's the Zippers ThunderMax description:

ThunderMax AutoTune Module

The ThunderMax AutoTune Module works with your ThunderMax Electronic Fuel Injection (EFI) controller to create a Wide-Band Closed Loop EFI System. Add pipes, change cams – AutoTune’s on the job! The ThunderMax AutoTune processes feedback from two wide-band oxygen sensors to adjust the fuel volume at all RPM’s and throttle positions. These sensors continually provide feedback for corrections to the fuel map values for optimum performance, Custom-Tailoring the Fuel Map for your application!

The AutoTune kit consists of two wide-band (5 wire) oxygen sensors and a small module that interprets and converts data from the sensors, which is then fed electronically through the J1850 serial bus wiring through the data port plug found on all Twin Cam motorcycles. This means that if you have sensor bungs in your exhaust pipes, the physical installation consists of simply screwing in the oxygen sensors, plugging them into the AutoTune module, then plugging the AutoTune module into the data-port plug and you're done – no wire cutting or splicing!

Next, use SmartLink software to automatically convert your open-loop map to closed-loop format and download the map to your ThunderMax EFI module. Simple? You bet! Many of the exhaust pipe manufacturers are getting on the bandwagon and will be supplying pipes with bungs in them, and not just for 2007 motorcyles.

D&D comes to mind as the first to do this.

So what exactly does the ThunderMax EFI AutoTune system adjust?

It adjusts fuel for a target Air/Fuel Ratio (AFR). The module (software, really) has user-selectable targets for the AFR on 32 RPM pages (every 256 RPM), at 64 points on each page (that's over 2000 points if you're counting). While this sounds like a lot, they are easy to adjust with point-to-point fill commands, meaning you can move blocks of target AFR points with just a few clicks. You can really concentrate on a certain area such as cruise RPM for fuel economy or richen up full throttle maps for best power. If individual point or map adjusting doesn't interest you, you can choose to override the individual map pages with a straight, across-the-board AFR at all points by entering the desired AFR in the AFR Override dialog and a single AFR you will get. The AFR default is currently set to 13:1 on all of the AFR/TPS at RPM pages; it provides a good balance of power and economy. You can adjust with AutoTune from there.

How much will it adjust?

Quite a lot, actually. Up to 50% from the installed base map. How important is the base map? It's still advisable to install the closest base map in our system for your application to minimize the system's learning time. There are two learning controls within the software that you can set. The first is how much learning the system can do per session (a session being defined as ignition-on to ignition-off, per cycle). The range per session is 0-50%; for a close or dead-ringer match map, we recommend using the default setting of 5% (use more if you have a combination that is a mismatch, for faster learning). The second is the total amount of learning, regardless of the number of sessions; the range is also 0-50%, default here is 20%.

No splicing necessary; plugs into the factory wiring harness for easy installation.New SmartLink software and firmware will automatically convert all existing open loop maps to a closed loop format.

The stock ECM was disconnected and removed by unscrewing four Allens. Two of ours pulled the brass grommets loose from their plastic base.

“Don't use Loctite on these,” Gene said. He had a trick to repair the mounting plate. He drilled out the bolts. “Most of the time, the heat caused by drilling cements the brass grommets back into place. Sometimes I glue them and sometimes the plate needs to be replaced.” Everything needed to be installed before the fuse was replaced. The existing data link connector now controls and powers the 02 sensor heaters. Gene left the fuse block loose, so he could access the fuse position.

With the fuse in place, Gene turned the ignition on for 30 seconds. He turned it off for half a minute, then back on again, three times. That exercise allowed the ECM to sink with the throttle position sensor (TPS). He plugged in his computer and searched for the base maps. There are 400 to choose from. Your base map can be off by as much as 20-50 percent and the ThunderMax will find its way to optimum performance. Displacement is most important, so we plugged in 88 inches. The software led us to the 88-inch configurations, then we answered the questions asked about the throttle body and selected the D&D fatcat exhaust system, right click. Then we searched for the latest map made and loaded this puppy. We checked the rev limiter, speedo calibration and lowered the idle for that throaty rumble.

The accelerator pump can be adjusted and between 8 and 15 is normal. The decelerator mixture can also be adjusted to prevent rich mixture popping. There is also a hot engine alarm and we checked the setting at 350 degrees. All the basic settings were checked and we turned the bike on.

On the top of Gene's computer screen he right clicked his key pad to link all the selections to the Thundermax ECM system. Then he watched for the auto-tune square to turn green to indicate the selections were accepted.

Just to be on the safe side, Gene turned the ignition off, unplugged the computer, turned the ignition back on and plugged the computer lead back into the ThunderMax body. He double checked to verify that his selections were accepted and we were ready to test.

We warmed the bike until the head temp was at least 180 degrees then prepared for dyno runs. Each time the bike is turned off and one, it will make as much as a 5 percent adjustment until it run perfectly. As mentioned above in the description, the ThunderMax will adjust up to 50 percent of the original map chosen to reach optimum performance.

We shut the computer down and used Gene's dyno for our first test and were amazed at the findings. We say an almost 20 percent increase in power and a very consistent power curve. Our torque remained the same but increased the rpm range three fold from top torque from 300 rpms to 2,500 rpms at nearly the top torque.

Check the charts. “Keep in mind that this system delivered the equivalent of a new, bigger inch engine,” Gene pointed out. This chrome Bandit Kit retails for only $1,798.00 and the black Bandit Kit comes in at $1,898.00. You retain smaller engine reliability and get $8,000 engine performance. Not bad.

MAKE BIG HORSEPOWER IN YOUR OWN GARAGEIt’s spring time and you want a little more lead in your pencil. Where do you go? Go no farther than D&D’s New Bandit Kit – It makes asphalt ripping performance for your Harley-Davidson fuel injected motorcycle. The Bandit Kit comes with a D&D performance exhaust pipe, high-flow air cleaner and Zipper’s Performance ThunderMax with AutoTune tuner. And we will provide a 15% discount just by mentioning the Bandit Kit!

Save 15% on The Bandit Kit – Call 817-834-8961 Now!

All the experts agree that the most cost effective upgrade to your motorbike is a performance pipe, a free-flowing air cleaner and a tune up. The Bandit Kit delivers it all in one easy to use and to install package from D&D Performance Enterprise.

Your Performance Hotline – 817-834-8961

The Zipper’s Performance ThunderMax with AutoTune tuner calibrates itself so you don’t need to put your bike on a dyno. That saves time and money. Also, if you add more go-fast parts, it knows it and modifies itself. Fast, efficient and easy to use – that's the D&D way.

So call the D&D team today at 817-834-8961 or get more information by here and start making horsepower gains tomorrow.

Call D&D Performance Exhaust at 817-834-8961 for details. Tell 'em you want the Bandit system.

Please follow and like us: