My friend Wayne just bought a 2013 Harley Davidson Tri-Glide and was complaining it needed some more power to get down the highway. Even with the 103 CI Twin Cam engine that is not surprising because of the weight of the motorcycle.
We decided to go with a Zip Kit package from Zipper Performance that included an exhaust header (he already had screaming eagle mufflers), high flow air cleaner and ThunderMax tuner. The ThunderMax also allows you to download new maps in the future should you do any other performance upgrades.
The exhaust is a Dual Header System from Khrome Werks. The “True Dual” is made of 1 3Ž4 16 gauge material and comes with full coverage heat shields. It is designed for maximum top end power and improved low end torque with balanced flow.
I started off by removing the stock exhaust system. This is basically starting at the back removing the mufflers and moving forward until all parts were removed. This procedure is covered in the Harley Manual and also with the instructions that comes with the new exhaust.
I then replaced the exhaust gaskets using JIMS tool number 788. It makes the install quick and easy.
The exhaust comes with both 12 & 18MM bungs installed. I would be using the 18 MM O2 sensors from ThunderMax so I installed the 12mm plugs. In the next step I varied slightly from factory supplied instructions by installing the exhaust system and then the O2 sensors because it was easier for me.
The header system is installed by inserting the front pipe into the exhaust port and then the rear by using a strong pull to seat it. Once in position the flanges were installed on the studs, neversieze was used on the studs and the saved 5/16-24 flange nuts installed. The nuts were Snugged but Not Tightened at this time. The O2 Sensors come with neversieze on the threads and I installed them. Note; Do not over tighten because once you have run the motorcycle, heat from the exhaust will make them tighter and could be a problem if they ever have to be removed.
After the header was installed Neversieze was applied to all exhaust pipe connections and the cross over installed followed by pipe extensions (because it is a trike) and then the mufflers. There are detailed instructions that should be followed while doing this. After the exhaust is in place follow the enclosed tightening instructions. The complete installation instructions can be found at
http://www.khromewerks.com/PDF%20Files/Instructions/High%20Performance%20Exhaust/200650A.pdf
Now that the exhaust was installed I removed the air cleaner cover, element and plastic backing plate. I retained the cover mounting screw, 2 breather bolts and “S” shaped hoses.
I used Blue Loctite on the original breather bolts inserted them through the supplied spacer and tightened them securely.
Next I installed the “S” shaped hoses through the new backing plate and chrome caps. Using Blue Loctite on the threads of the stanchions I installed the bottom one through the new backing plate and gasket and into the throttle body then pushed the hoses over the nipples of the breather bolts followed by the chrome caps. I then installed the two other stanchions and tightened to 85 inch pounds in sequence, repeating this a couple of times to seat the gasket and then went to 90 inch pounds for a final torque.
Next the filter element was lined up with the stanchions and the screws provided installed after a small amount of Blue Loctite was applied to the threads.
While I was doing the above I had added some silicone to the air cleaner cover gasket, installed it, and laid it on a flat surface with some weight on the cover to let it set up. Now that it had I added some silicone to one side of the thick supplied washer that was to be used as a spacer. Though some people use Blue Loctite on the cover screw I prefer to use Liquid Teflon. Putting the bolt through the cover and placing the spacer over it with the silicone side towards the filter element the cover was lined up and tightened in place.
Detailed instructions can be found at http://www.zippersperformance.com/pdf/117-448,%20117-449%20%20Air%20Filter.pdf
The next step was installing the ThunderMax. Remove the side cover and the main fuse, followed by the seat. The factory ECM is held in place by plastic caddy latches, simply pull back on them and remove the unit. Holding it firmly remove the lock and slide the release lever to remove the wiring harness from the ECM. This is covered in detail in the supplied instructions and they should be followed carefully.
I routed the front sensor wire across the front brace and then along the right side frame rail making sure it did not touch anything. The rear wire was routed between the transmission cover and the starter and then to the ABS caddy located on the right side of the motorcycle.
I lubed the communication and Auto Tune cables with dielectric grease and installed them into the ThunderMax ECM making sure they were fully seated and then secured them.
The ThunderMax was then installed into the caddy and the other wires greased and joined. I then double checked the wire routing and secured it to the frame with wire ties. I then re-installed the main fuse, the warning sticker about removing the battery in the future and then the seat.
Since I had purchased the unit directly from Zippers it came pre-programmed and I started the motorcycle. I let it warm up, shut it off and then repeated the procedure. I was happy with it so I reinstalled the side cover and took it for a ride. OH YEA!!! A Major Difference and it would get even better as Wayne rode it. He has since gotten back to me and has recommended it to some of his other trike riding friends.
For those who purchase the kit or the ThunderMax from other sources it does come with detailed instructions on how to install the proper map. If you have any issues there is an excellent support staff available to help.
Detailed install instructions for the ThunderMax can be found at http://www.zippersperformance.com/media/wysiwyg/DownloadsPDFs/ThunderMaxInstructions/309-362_Installation_V2012.06.28.pdf
For more information on this and other fine products for you motorcycle Zippers web site is. http://www.zippersperformance.com/
