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[cahdbiker]

Please see my original post regarding this on problem on my 09SEUC. I will be glad to send you several pictures of what I think is an OK remedy, but I can't seem to figure out how to send more than one picture at a time. Just in case you missed my original post the part I used for what I feel is a fix for this problem is the stock braket that held the air cleaner cover on before the SE kit was installed. It has part no. 29644-08 stamped on it and I bet a lot of you guys have one of these laying around.The 3 screws that hold the bracket to the air filter should be slightly longer than the ones that come in the SE air filter kit since the bracket is about 3/16 thick.CAHDBIKER

[Diamondback]

 

Great solution.  Should have come with the Stage1 kit.

 

[RetSUBLDO]

Does the stock AC cover hit the top of the filter element?  Looks like the offset of the threaded mounting hole might cause a problem. 

Eric

[cahdbiker]

Does the stock AC cover hit the top of the filter element?  Looks like the offset of the threaded mounting hole might cause a problem. 

Eric

Eric, Thed top of the air cleaner does not make contact with the air filter element, although it is very close because as you can tell by the picture the bolt hole for the center bolt of the air filter cover is lower. CAHDBIKER

[Jerry/MD]

Eric, Thed top of the air cleaner does not make contact with the air filter element, although it is very close because as you can tell by the picture the bolt hole for the center bolt of the air filter cover is lower. CAHDBIKER

That's good news. Thanks for the pic and info CAHDBIKER. I still have my bracket and will use your fix...because I like the stock cover.

Did you buy longer screws? If so, where did you find them?

[grc]

While it looks like the bracket material is thicker and stronger than the end cap of the filter element, I don't know if you can just assume that the nut won't break out of that bracket just like it does from the filter.  The cover is still only supported by that center bolt.  And that bracket was designed for use with the entire outer edge of the stock airbox supporting the cover, not just that nut.

It's probably more secure than just screwing the cover to the filter, but I think I'd still be looking for something to actually support the cover for a full 360° over the largest area possible.  JMHO.


Jerry

[skreminegul07]

While it looks like the bracket material is thicker and stronger than the end cap of the filter element, I don't know if you can just assume that the nut won't break out of that bracket just like it does from the filter.  The cover is still only supported by that center bolt.  And that bracket was designed for use with the entire outer edge of the stock airbox supporting the cover, not just that nut.

It's probably more secure than just screwing the cover to the filter, but I think I'd still be looking for something to actually support the cover for a full 360° over the largest area possible.  JMHO.


Jerry

Jerry,
The stock 2007 SERK air filter had a thick rubber gasket maybe 3/8" or more that served that purpose.  What I never understood is that the gap came from a steel spacer of the same thickness that was welded just behind the center mounting bolt.  I removed the spacer and then discarded the rubber gasket and it sat in full contact to the circumference of the air filter. 

[Jerry/MD]

While it looks like the bracket material is thicker and stronger than the end cap of the filter element, I don't know if you can just assume that the nut won't break out of that bracket just like it does from the filter.  The cover is still only supported by that center bolt.  And that bracket was designed for use with the entire outer edge of the stock airbox supporting the cover, not just that nut.

It's probably more secure than just screwing the cover to the filter, but I think I'd still be looking for something to actually support the cover for a full 360° over the largest area possible.  JMHO.


Jerry

The only way to get 360° degree support is to use the original plastic backing plate. That design supported the entire circumference of the cover.

This whole discussion proves once again H-D has it's head up you know where! The Stage 1 upgrade is probably the most popular mod...and it has a known design flaw. Just great. 

[grc]

The only way to get 360° degree support is to use the original plastic backing plate. That design supported the entire circumference of the cover.

This whole discussion proves once again H-D has it's head up you know where! The Stage 1 upgrade is probably the most popular mod...and it has a known design flaw. Just great. 

Not really, although that is what the original design intended.  What I meant was that while adding that bracket takes the stress off the thinner material of the filter at the center nut, is still doesn't address the fact that the cover still isn't supported well enough to prevent vibration and movement.  You're still hanging a big heavy cover from one point, basically, and the extra bracket moves that heavy load further out from the attachment point creating even more stress at the three smaller screws and standoffs.  The potential still exists to break out the material at the three smaller screws, or even snap off the screws or the standoffs.  Some folks have had those break with certain Zipper's filters, btw.  The best approach is to maintain full contact with the rubber gasket on the end of the filter and at the center nut.  And that is going to require either adding material to the interior of the cover, or fabricating that 5" diameter washer we talked about and epoxying it to the cover, or something similar. 

I don't have a dog in this hunt, and I probably should shut up, but I don't like watching people walk into problems without at least offering a warning.  Lacking a ready-made solution, which wouldn't be hard at all for someone like H-D to create if they really wanted to, I think the typical owner of a CUSEx should probably just buy a cover designed to work with the round filter and hang the stock cover on the wall as a decoration.  I'm still convinced that I could make this work by modifying the interior of the cover, but since I don't have one I can't actually prove it.   

BTW, don't forget to seal up that center hole in the filter if you decide to use the extra bracket instead.


Jerry

[cahdbiker]

That's good news. Thanks for the pic and info CAHDBIKER. I still have my bracket and will use your fix...because I like the stock cover.

Did you buy longer screws? If so, where did you find them?

Jerry/MD, I got the screws at my local True Value Hardware. The are hex heads are are only slightly longer then the ones that came out to make up for the thickness of the plate I added. CAHDBIKER

[cahdbiker]

Hi Jerry, As always thanks for your input.  If K&N would make the metal in the front of the air filter a little thicker we would not be having this issue. Mine broke out in a almost perfect circle about the size of a quarter at the base of the protrusion where the center bolt normally goes. I noticed on the my replacement K&N  filter ( which was replaced at no charge) that there is a small circle at the base of the protrusion exactly where my old one broke. So instead of making the metal in the front of the air filter thicker K&N just pushed it out and attached a thick washer with threads to the inside of it. That is the problem. The bracket I installed is quite thick and very strong due to the channel in the center where the stock air filter cover is attached. I think that since the weight of the air filter cover is distributed among the three screws which attach to the mounting studs if anything breaks it will be the air filter cover itself. By the way thanks for reminding anyone who uses this fix to seal up the center hole. I used a bolt as shown in the picture. Thanks again for your input. CAHDBIKER

Not really, although that is what the original design intended.  What I meant was that while adding that bracket takes the stress off the thinner material of the filter at the center nut, is still doesn't address the fact that the cover still isn't supported well enough to prevent vibration and movement.  You're still hanging a big heavy cover from one point, basically, and the extra bracket moves that heavy load further out from the attachment point creating even more stress at the three smaller screws and standoffs.  The potential still exists to break out the material at the three smaller screws, or even snap off the screws or the standoffs.  Some folks have had those break with certain Zipper's filters, btw.  The best approach is to maintain full contact with the rubber gasket on the end of the filter and at the center nut.  And that is going to require either adding material to the interior of the cover, or fabricating that 5" diameter washer we talked about and epoxying it to the cover, or something similar. 

I don't have a dog in this hunt, and I probably should shut up, but I don't like watching people walk into problems without at least offering a warning.  Lacking a ready-made solution, which wouldn't be hard at all for someone like H-D to create if they really wanted to, I think the typical owner of a CUSEx should probably just buy a cover designed to work with the round filter and hang the stock cover on the wall as a decoration.  I'm still convinced that I could make this work by modifying the interior of the cover, but since I don't have one I can't actually prove it.   

BTW, don't forget to seal up that center hole in the filter if you decide to use the extra bracket instead.


Jerry

[Jerry/MD]

Not really, although that is what the original design intended.  What I meant was that while adding that bracket takes the stress off the thinner material of the filter at the center nut, is still doesn't address the fact that the cover still isn't supported well enough to prevent vibration and movement.  You're still hanging a big heavy cover from one point, basically, and the extra bracket moves that heavy load further out from the attachment point creating even more stress at the three smaller screws and standoffs.  The potential still exists to break out the material at the three smaller screws, or even snap off the screws or the standoffs.  Some folks have had those break with certain Zipper's filters, btw.  The best approach is to maintain full contact with the rubber gasket on the end of the filter and at the center nut.  And that is going to require either adding material to the interior of the cover, or fabricating that 5" diameter washer we talked about and epoxying it to the cover, or something similar. 

I don't have a dog in this hunt, and I probably should shut up, but I don't like watching people walk into problems without at least offering a warning.  Lacking a ready-made solution, which wouldn't be hard at all for someone like H-D to create if they really wanted to, I think the typical owner of a CUSEx should probably just buy a cover designed to work with the round filter and hang the stock cover on the wall as a decoration.  I'm still convinced that I could make this work by modifying the interior of the cover, but since I don't have one I can't actually prove it.   

BTW, don't forget to seal up that center hole in the filter if you decide to use the extra bracket instead.


Jerry

I completely agree with all of your points. As usual, you point out areas of concern the rest of us miss.

I just find it a bit annoying you have to jump through this many hoops for a dang air cleaner cover. It shouldn't be this hard.

Jerry/MD

[Jerry/MD]

Jerry/MD, I got the screws at my local True Value Hardware. The are hex heads are are only slightly longer then the ones that came out to make up for the thickness of the plate I added. CAHDBIKER

Thanks for the info. I have a local Ace Hardware that stocks a nice selection of bolts and screws too.

I think I will remove the filter this weekend and see what I can do to provide the correct support. Wish me luck.

[US.Army.Retired]

Good luck and keep us posted