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[Screamin]

So I'm buzzing down the turnpike about 70 and hear a clang and see something silver bouncing along the road behind me. Where'd that hup cap come from? Never saw it in the road. Oh well, we all missed it. Buddy pulls up and points at my right leg. WTF, my fricking air cleaner's gone. #&@! Oh well, I'm still movin so I'll figure it out when I get there. Get there and WTF? All three bolts holding the filter are busted off inside the housing. WTF?
Make a speed run down to Harley Davidson Sales in Napoleon, OH and they get me right in and drill out the busted bolts and stick on a filter. OUTSTANDING SERVICE!! But they wouldn't warranty the stage one kit, said that HD said no. Sucks . Now to try the dealer that installed the get. We'll see.
Oh yeah, '05 Eglide.

[WFP]

Similar thing happened to someone in Cripple Creek last June...do we see a trend starting to form???

[txbear55]

Ditto!!!  Happened to me with the Zippers hi-flow ac.  The metal fatigued and broke out where the cover bolts to the filter.  Zippers has yet to remedy the situation as they said they would several weeks ago.  Starting to get pi$$ed with their lack of customer service.

[arcticdude]

My stock center bolt loosened up durnig the Cripple Creek ride.  Glad I heard the noise and tightend it before any damage was done.  I grab the air cleaner every now and then now.

[grc]

So I'm buzzing down the turnpike about 70 and hear a clang and see something silver bouncing along the road behind me. Where'd that hup cap come from? Never saw it in the road. Oh well, we all missed it. Buddy pulls up and points at my right leg. WTF, my fricking air cleaner's gone. #&@! Oh well, I'm still movin so I'll figure it out when I get there. Get there and WTF? [highlight]All three bolts holding the filter are busted off inside the housing. [/highlight]WTF?
Make a speed run down to Harley Davidson Sales in Napoleon, OH and they get me right in and drill out the busted bolts and stick on a filter. OUTSTANDING SERVICE!! But they wouldn't warranty the stage one kit, said that HD said no. Sucks . Now to try the dealer that installed the get. We'll see.
Oh yeah, '05 Eglide.

Screamin,

Were these the 3 long mounting studs broken off in the throttle body, or the 3 short screws that actually attach the filter to the long mounting studs?  Either way, hard to figure how they could break.  The torque spec for the studs and for the screws is only 55-60 in-lbs, which should be well below the yield strength of the parts.  If it was a case of overtightening to the point of fracture, I would think the brass inserts in the TB would have failed first.  Of course, the other option is that somehow you managed to get three defective studs. This is a real head scratcher.

Jerry  

[Twolanerider]

At Cripple Creek it was Jonga.  I'd only ever heard of one other bike doing that before then.  Now Jonga's, yours, and one other here locally make three in a month's time.  Weird.

[jdk20723]

JK from Zipper's here.  We've had a few calls this year (less than 10) of folks who have experienced stud breakage at the backplate, which caused us to look at this part pretty closely.  We've been selling this same stud/stanchion setup (thousands!) since early 1999 (same as used with our 8" EV-style filter) with no problems, so if there is an issue with the design, it would have surfaced long ago.  However, there could be an issue with a batch of the threaded studs themselves actually being over-heatreated, causing them to be brittle and prematurely break (they are supposed to be of grade 8 strength due to the hex socket on one end would just round out otherwise).  

But because any failure is a concern, we tested the same brand steel studs we've been using along with 3 other brands, all claim grade 8 strength.  We found that they would all fail (snap!), in a special fixture we used in a press, at about 4 tons of press.  Which lead us to believe that the cause of the failed units is isolated, probably an over-heatreated batch of studs.  

We have a Rockwell hardness tester here, but the studs are difficult to test due to their size and design, so rather than guess that the heat treat is OK, we looked at different materials and found a stainless steel material that went past 5.5 tons before it spit out the the fixture, deformed but intact (no breakage).  For peace of mind, we have since changed to this stainless stud.  

At any rate, txbear55 please contact us, or me directly at Zipper's.  If anyone else has any problems, please contact us.  If you wish to check yours and see something you don't like, contact us for replacement parts.

As always, thanks for using our products.  JK

[Coolbreeze]

I lost the three small studs that go into the Throttle body, and that was on a Arlen Ness filter assembly.  I think the CVO's just don't like football lookin' covers!

[txbear55]

JDK,  Thanks for the acknowledgement.  You will hear from me pronto!

[jfscheck]

Hey JDK -
Great air filter - can't wait till this winter when I bring the bike on over for some Zippers work!  

Go Terps!!!  [smiley=drink.gif]

[ace4059]

Ditto!!!  Happened to me with the Zippers hi-flow ac.  The metal fatigued and broke out where the cover bolts to the filter.  Zippers has yet to remedy the situation as they said they would several weeks ago.  Starting to get pi$$ed with their lack of customer service.

DON'T " PI$$ OFF" THE BEAR!!!

[txbear55]

Preferably not on, either!  

[Twolanerider]

JK from Zipper's here.  We've had a few calls this year (less than 10) of folks who have experienced stud breakage at the backplate, which caused us to look at this part pretty closely.  We've been selling this same stud/stanchion setup (thousands!) since early 1999 (same as used with our 8" EV-style filter) with no problems, so if there is an issue with the design, it would have surfaced long ago.  However, there could be an issue with a batch of the threaded studs themselves actually being over-heatreated, causing them to be brittle and prematurely break (they are supposed to be of grade 8 strength due to the hex socket on one end would just round out otherwise).  

But because any failure is a concern, we tested the same brand steel studs we've been using along with 3 other brands, all claim grade 8 strength.  We found that they would all fail (snap!), in a special fixture we used in a press, at about 4 tons of press.  Which lead us to believe that the cause of the failed units is isolated, probably an over-heatreated batch of studs.  

We have a Rockwell hardness tester here, but the studs are difficult to test due to their size and design, so rather than guess that the heat treat is OK, we looked at different materials and found a stainless steel material that went past 5.5 tons before it spit out the the fixture, deformed but intact (no breakage).  For peace of mind, we have since changed to this stainless stud.  

At any rate, txbear55 please contact us, or me directly at Zipper's.  If anyone else has any problems, please contact us.  If you wish to check yours and see something you don't like, contact us for replacement parts.

As always, thanks for using our products.  JK

JK, you dropped the ball a bit there.  In being such a great businessman and dropping in to explain the efforts you'd made you forget your audience here was a group with the worst OCD on the planet.  You could have offered up a part number and a sawbuck price for a set of three of the new stainless bolts and sold 20 sets in a heartbeat   .

[Screamin]

JK, you dropped the ball a bit there.  In being such a great businessman and dropping in to explain the efforts you'd made you forget your audience here was a group with the worst OCD on the planet.  You could have offered up a part number and a sawbuck price for a set of three of the new stainless bolts and sold 20 sets in a heartbeat   .

Hell I'd buy 'em . At $120 just for the Screamin Eagle cover plate I'd pay a little for the piece of mind!!

[jdk20723]

Don, I guess I wasn't clear enough.  If you have OUR filter and the earlier steel studs (easily identified by the hex socket in the end of the stud), I will ship the stainless replacements no charge.  Please provide an invoice number or some proof of purchase when you call.  Contact Bill Lam at 410.379.0909 x107.

As a side note, we don't recommend using our filter upgrade kit or complete filter kit with the 2006-07 SE 103/110 air filter cover due to the design of the new cover.  This newer oval cover does not have the round indent that fully seats on the filter rubber for proper support; it relies on the stock plastic backplate contacting the outer edge of the cover for support.  While it does bolt on, we don't think it will live long with only the top and bottom edges contacting the outer rubber seal on the filter.  For the record, H-D says their SE filter kit fits all models EXCEPT 2006+ SE bikes.  For these bikes, we recommend a K&N replacement filter and drilling some extra breathing holes into the back of the stock plastic backplate.   Thanks, JK