K & N AIR FILTER INSTALL / PCV
Not to bad of an install. Start by removing the hood and all panels. Gauge pod has to be moved(remove the plastic rivets) and un hook the key switch and wire harness to gauge. Next remove the headlight pod. Lots of wires here to take note of how they are routed. I just put it all to the side of the sled. I have extra gauges installed(temp &oil) so it was interesting. I didn't bother unhooking them, didn't really see the need.
I removed the handle bars and laid them on the tank. Only 4 bolts hold it on. Next the steering post has to be removed so you can get at the air box.
I wish I had installed the air filters when I did my steering post relocator. Oh well just one more step. Remove the nuts and just lay the post to the chain case side.
I removed the lid on the air box and removed the radiator shroud. Next I loosened up the 3 clamps holding the air box to the throttle bodies. You will need a
4mm ball end allen wrench to loosen the clamps. Remove two bolts holding the front of the air box. There are three hoses around the throttle bodies connected to the air box that have to removed when pulling up on the air box. The rubber air horns can be removed now. They are glued on so you have to work them around to loosen the glue.
Now we are in business.
I took some carb cleaner and cleaned the air horns.
Now the plastic rings can be installed on the air horns and clamp the air filter to the rings and air horns. Do not over tighten.
I used a small bit of Sikaflex adhesive to fill in the crack around the plastic rings after I had the filters on and tightened to the horns.
Install the idler speed control breather, then install the oil tank breather and valve cover vent line to oil tank breather. I think I installed these last.
Almost done. Time to install the air filters onto the throttle bodies. Make sure they are fully seated and then tighten the clamps with your ball end allen wrench. Also, Ulmer suggested to remove the gold spacer from the clamps so you can tighten a bit further.
I just want to comment that Ulmer's Instructions are great. Very clear and easy to follow. I have ordered several mods from him and he provides great customer service as most know. A+
Here is a pic with the filters installed.
Another pic. The bracket idea is from TY member Nikolia. Thanks by the way.
Used a few ties to help out and it is solid. Absolutely no worries about them coming loose or falling off.
Ok, start putting everything back to gether.
Oh the air temp sensor that was on the air box has to be removed and plug it in the wire harness. More ties come in handy.
I put the PCV USB on top of the rad cover with the velcro provided. Just unplug the 16 pin connector on the left side behind the rad and plug the USB connectors into the stock connectors. Easy as pie. Attach the ground wire to the negative terminal on the battery. Done. Ulmer has map already pre loaded.