Instructions
Below you will find the install instructions for the T-TWIN Cam Oil Pressure Gauge, M8 Oil Pressure Gauge, and the Ventilator. and A 1 pipe
A1 pipe install.
STOCK EXHAUST SYSTEM REMOVAL ● 1. Remove both left and right saddlebags and set them aside. Remove the right side panel. ● 2. Loosen the pinch clamp bolt on the front end of the muffler(s). ● 3. Remove the two 5/16” bolts and washers that mount the muffler(s) to the saddlebag supports. Save these for re-use. ● 4. Remove the stock muffler(s) and set aside. NOTE: It may be necessary to use a penetrating lubricant to loosen muffler(s) from the head pipe. ● 5. Locate and unplug the O2 sensor wires from the wiring harness (Grey and Black connectors located behind the right side panel) and remove cable ties holding wires to the frame. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. ● 6. Remove the right hand floor board. ● 7. Loosen head pipe clamp connecting the left side muffler to the header and the mount bracket on the backside of the oil pan. Remove the crossover section from the head pipe and the head pipe clamp. ● 8. Remove the mount clamp located behind the oil pan. The mount and bolts will not be reused. ● 9. Remove nuts from the front header pipe mounting bracket and stud. ● 10. Loosen the heat shield clamps on both front and rear exhaust pipes. ● 11. Remove the two flange mounting nuts from each head pipe ● 12. Carefully remove the O2 sensors from the stock head pipes and save for reuse with the new system. ●13 throw in dumpster
● 1. Remove the two bolts from the transmission cover. Position the mounting bracket over the mounting location to determine which bolts to remove. ● 2. Attach your supplied transmission bracket to the transmission reusing the OEM bolts and washers. Don’t tighten all the way down at this time you may need to position the bracket to fit the correct angle of the muffler. reinstall the transmission cover ● 3. Apply a small amount of anti-seize compound to the threads of the O2 sensors and install them into the new head pipe. install 12mm oxygen sensors ● 4. Install the front header first and then the rear header assembly into the exhaust port first using the supplied exhaust gaskets. Use the stock flange nuts, do not tighten at this time. Now install the muffler. Using the supplied 5/16- flange bolts , secure to the hanger bracket. Leave them loose at this time. ● 5.This next step is critical to check rotation of the muffler and the head pipes to get proper angles for the mounting bracket and clearance on the head pipes around the engine and floorboards. There’s a lot of movement at this point to get the angles correct. You may need to adjust the trans bracket to get the correct angle to the muffler, tighten down to correct OEM specs 22-25 ft lb. ● 6. Now tighten down the head pipe flange bolts to around 20ft lb . Tightening them down evenly. Lastly, tighten the two muffler bolts. ● 7. Route O2 sensor wires away from hot areas of the motorcycle. Plug the O2 sensor wires back into the wiring. ● 8. On floor board models, re-install and tighten the floorboard mounting bolts or install needed spacers. ● 9. Be sure to tighten all hardware before starting the motorcycle. After installation and before starting the motorcycle, completely clean pipes and mufflers with soap and water then brake cleaner and a clean towel, any fingerprints will be burned on forever (18mm bung plugs are supplied please never seize and install dyno guy will love you for it)
You must tune your bike immediately this pipe flows differently than any other pipe on the market. Your canned map or buddies tune will not work, PERIOD!!!!
T-Twin Cam Oil Pressure Gauge Directions
1) Disconnect battery and make sure the bike is cooled off.
2) Locate the oil pressure sending unit at the front of the bike behind the front exhaust down pipe, your exhaust may need to be loosened up and rotated out to get at the fitting . remove sending wires and then unscrew oil pressure sending unit.
3) Once removed install adapter fitting into case, tighten securely its pipe thread, tighten snug and make sure the fitting hole is pointed upwards towards top of engine, re install oil pressure fitting, re-connect sending wire or wires. It will get tighter the more you turn it in..you want this snug without stripping threads. (Use common sense please)
4) Move up to rear rocker box right side, remove the 2 rear rocker box bolts, install gauge with new supplied bolts (a drop of blue loc tite doesn't hurt but not required) torque to 18 ft pounds.
5) Thread oil line with 90 degree end onto front oil fitting route behind front push rod tubes but behind air cleaner take time routing it every air cleaner is different, the rubber line is very high temp silocone and will not melt against engine but will melt if it touches exhaust, run line to gauge, do not overtighten.
6) When tightening line to gauge and motor fitting use 7/16" wrench on oil fitting in case and tighten 7/16' line fitting, then move to gauge and hold adapter fitting with 9/16" wrench and tighten 7/16" nut on oil pressure line… YOU MUST HOLD BASE OF FITTINGS TO TIGHTEN DO NOT JUST TIGHTEN WITH 7/16' WRENCH OR DAMAGE WILL OCCUR!!!
7) Reconnect battery and tighten exhaust if moved to install, start motorcycle and check for oil leaks...enjoy!
8) WE DO NOT KNOW YOUR BIKES STANDARD OIL PRESSURE, EVERY CASE, FILTER, CASTING, PUMP, OIL TYPE AND TEMP WILL VARY READING..PLEASE DO NOT EMAIL, CALL OR TEXT ABOUT WHAT SHOULD MY GAUGE SAY.. IF YOUR OIL LIGHT IS ON AND YOU HAVE PRESSURE (A COMMON PROBLEM) FEEL FREE TO RIDE YOUR BIKE UNTIL SENSOR IS FIXED.
M8 Oil Pressure Gauge Install
1) Disconnect battery and make sure bike is cooled off
2) Locate pressure pipe plug at front bottom of motor this is the galley that supplies oil to the filter 2 possible places to remove factory oil plug (SEE PHOTOS) , your exhaust may need to be loosened up and rotated out to get at the plug with an allen wrench or remove front cooler and regulator mount to use an extension and allen socket on a ratchet.
3) Once removed install 1/4 npt pipe to -3 an fitting in place of plug..this requires a 5/8" wrench . get this snug, Teflon tape or pipe dope is not required but if you have some don't overuse it) it is a tapered thread and will seal tighter the more you turn it in..you want this snug without stripping threads. (use common sense please)
4) Move up to rear rocker box right side, remove the 2 rear rocker box bolts, install gauge with new supplied bolts (a drop of blue loc tite doesn't hurt but not required) torque to 120 inch pounds
5) Thread oil line with 90 degree end onto front oil fitting route behind front push rod tubes but behind air cleaner . take your time routing it every air cleaner is different, the rubber line is very heat resistant it can touch the motor but not the exhaust , run line to gauge, do not over tighten.
6) When tightening line to gauge and motor fitting use 5/8" wrench on oil fitting in case and tighten 7/16' line fitting, then move to gauge and hold adapter fitting with 9/16" \wrench and tighten 7/16" nut on oil pressure line..YOU MUST HOLD BASE OF FITTINGS TO TIGHTEN DO NOT JUST TIGHTEN WITH 7/16' WRENCH OR DAMAGE WILL OCCURE!!!
7) Reconnect battery and tighten exhaust if moved to install, start motorcycle and check for oil leaks..enjoy
Ventilator Instructions
1. Stock Dip Stick
Oil level must be set a minimum of 4-5 dots down from full-on side stand fully screwed in. This must be done hot, ride bike 20-30 minutes then let idle upright while sitting on the bike for 2-3 minutes then check level. This is a predetermined level for the ventilator to have enough air space in the case to work. If it's over full, suck some out with turkey baster or drain from plug. If you do not do this step, your bike will be covered in oil.
2. Ventilator dipstick same procedure for checking as above, just please be same or just below the single mark on new dip stick.
3. The hose is American made gates true rubber hose for fuel and oil and has a 50 psi rating, and a 700 degree burn through rating...it will not burn touching your motor, unless your bike is on fire...
4. There is a reason we have you place filter on top of throttle body, it is not in direct wind to allow it to create a vacuum and pull oil up the hose and also protects it from rain.
5. The filter may be washed with carb or brake cleaner and air or compressed air dried then re installed no reason to oil or buy a new one
6. Your oil tank and crankcase are connected via a channel where the case meets the trans case...relieving the oil tank relieves the pressure in the bottom of the motor, as the pistons come down air is expelled out vent and then when pistons go on upstroke air is drawn in, it is a pulsing system so no need for a one way valve or a check valve. and on the intake stroke it draws in cool air to help coil oil
7. Any 3/8" internal passage hose may be used, decorate it, stainless, cloth, color wraps.. be creative, just be aware it is not our hose and it may have a lower melting point, watch the contact points.
8. Please watch all videos on home page www.a1cycles.net has full install and oil level videos
9. Once oil level is correct, screw cap in, put a little oil on threads, install filter on end of hose, feed hose from behind the air cleaner by the throttle body under tank over the rear rocker box and then down to the back of the fill cap connect and enjoy, on 2018 cvo and some oil fan models there is room to sneak it between fan and frame, I zip tie it to the coil wire boot to keep it from rubbing on anything
PAN AM RISER INSTALL
PAN AM RISER INSTALL
place bike on center stand or sidestand
place a towel on top of the tank
crack loose the top 4 riser bolts (torx 45)
pull front nose off (no tools just pull)
remove bottom riser bolts (t50)
bolts are upside down and hidden in a pocket of bottom tree with nose off no extensions required
finish removing top bar clamp bolts
layer bars on towel previously placed on top of tank
remove top handlebar clamps and bolts on new risers
install new risers to top of triple clamp (do not fully tighten)
lay bars into new risers bottom saddle
install top clamps and tighten with 3/8" 12 point socket or wrench (18 ft lbs.)
tighten bottom riser bolt (t50) (24 ft lbs)
function check bars side to side before riding, do not pinch wires or cables when tightening
enjoy
PAN AM HEEL GUARD INSTALL
remove existing plastic guards with torx 27
throw plastic garbage out
place small washers behind left heel guard (shifter side) its the shorter of the two
tighten to 7 foot pounds (94 inch pounds) (hand tight is fine)
install larger washers behind the right side heel guard (taller one, brake side)
tighten to 7 foot pounds (94 inch pounds) (hand tight)
you will see the right guard now protects your rear master cylinder completely
thank you