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HONDA 750 AERO Thunder Air Filter Kit Installation Instructions

November 1st, 2009 · No Comments

Congratulations on your purchase of the HONDA 750 AERO Thunder Air Filter Kit. We’re sure you’ll be pleased with the new level of performance you’ll experience. This kit should only be installed on bikes that have been jetted (jet kit not included). We recommend that an experienced mechanic perform this conversion. Use the appropriate Honda service manual for reference to complete jetting of carbs. Remember, gasoline is extremely flammable and can be explosive under certain conditions. Work in a well-ventilated area and clean up any spills immediately. Check for leaks before riding.

Read First
1) Remove seat (2)-6mm allen bolts under drivers seat (1)-8m socket at rear of passenger seat.
2) Remove dash (2)-5mm allen bolts at rear of dash, lift and unplug electrical connecters under dash.
3) Remove tank (1)-12mm socket at rear of tank, disconnect vent line at right rear under tank and disconnect fuel & vacuum lines at petcock. Now lift & remove tank.
4) Remove air box (2)-8mm sockets at front and rear of air box, loosen clamp around carb. mouth, and pop idle adjuster knob out of bracket at bottom of air box.
5) Set carb needle on third (3rd) groove from top. Use 132 MJ with stock exhaust. Set air fuel mixture screw 2 ― turns out.
6) INSTALL THUNDER AIRBOX. Remove stock velocity stack from stock air box, trim approximately 1 ―” off tapered end or ž” behind first rib at tapered end. Install trimmed velocity stack into Thunder Adaptor, it should clip or lock into place. Install Thunder Adaptor to bike using spacers and bolts supplied. Tighten hose clamp around carb. and tighten bolts holding Adaptor to bike. Now attach Thunder Air Kit backing plate to adaptor with (2)- 6×15 taper head bolts supplied, now attach filter and cover.
7) Install crank case filter into crank case breather line on top of rear cylinder and tuck under tank.

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