Removing the Stock Air Intake System on a Victory Motorcycle

With the basic need of all motorcyclists being the need for more horsepower. I decided to upgrade my Victory motorcycle from the stock air intake to a custom aftermarket air filter. Why? The stock air boxes are often too restrictive. They do not allow enough air to freely flow into the engine. The Victory stock air box is a mechanical suction. The air is sucked in through the left side of the coffin like air box. There are a few modifications that can be done to the stock filter to get a direct flow of air into the throttle bodies. But these require drilling ugly 1-inch holes in the front of your cheap looking plastic air box.

The theory behind this is that you will be producing a Ram-Air effect. This is where fresh yummy colder air gets forced in through the strategically drilled holes. Free flowing is the key, no ninety-degree turns and bends for the air to travel. This is all good, but you are still limited by what the stock Victory air box can provide. Especially when you upgrade the exhaust. With such an upgrade, you will need to be ingesting more air for the exhaust to work at its peak performance.

The other benefit of removing the stock air box and replacing it with a high-performance custom air box, is the esthetics of the look of the new air box in place of the stock air box. Some aftermarket high-performance air filter kits, like the Eaglecat, make your Victory look like a custom motorcycle once it is installed. This alone is reason enough to do the air box upgrade.

Having given the reasons why, let's now discuss the technical procedure for removing your stock Victory air box. We will follow up by showing you how to install one of the many aftermarket performance air box kits.

Victory Air Intake System Removal Instructions

Removal of plastic stock cleaner system, use owners manual if needed.

1. Remove side covers from bike (side covers pop on and off).

2. Remove seat by unscrewing (2) mounting bolts 6 mm allen head.

3. Remove gas tank rubber mounting bolt covers front right and left.

4. Remove gas tank mounting bolts (2) front and (1) rear 8 mm allen head.

5. Lift rear of gas tank slightly disconnect electrical connector and disconnect vent hose.

6. Loosen fuel line hose clamp and disconnect main fuel line, remove gas tank.

7. Disconnect and remove air temperature sensor.

8. Remove map sensor disconnect wires.

9. Remove air box cover (5) screws, lift out intake tubes.

10. Remove air filter cover and filter.

11. Disconnect crank case breather hose from air box.

12. Using a sharp gasket scraper or chisel and a small hammer split and separate stock plastic air box at it's seam. Remove top portion of plastic air box.

13. Unscrew (4) mounting screws that hold air box to throttle body. Remove bottom portion of plastic air box, save rubber gasket between plastic box and throttle body. You will be reusing this rubber gasket.

EagleCat EC-VAIR Air Intake System Install Instructions

(Note fuel injected bikes) aftermarket air cleaners are designed to be used with a fuel controller unit such as TFI / PC or factory mapping upgrades to prevent possible damage to the engine. Aftermarket air cleaners are also designed to be used with aftermarket exhaust systems or slip on mufflers for performance gain).

Installation of new air cleaner system.

NOTE SECOND GENERATION CAT BOX HAS REVERSE THE MAPPING AND TEMPERATURE SENSOR LOCATIONS

1. Remove top plate and filter of new air cleaner system.

2. Cut stock crank case hose, remove approximately a 5 inch section (you might want to mock up new crank case hose extension to get correct length needed).

3. Attach crank case hose extension to the hose you just cut using barbed nipple provided. Route hose extension to connect to barbed nipple mounted on underside of new air cleaner mounting plate.

4. Relocate map sensor to underside of new air cleaner bottom mounting plate using screw provided to secure it in place.

5. Reinstall stock rubber gasket between throttle body and new air cleaner bottom mounting plate.

6. Attach new bottom mounting plate with (4) 6 mm taper head screws provided, tighten (4) screws to 30 in-lb torque.

7. Install new air filter and top plate, (Note when installing top plate carefully tighten (2) mounting screws evenly.

8. install air temperature sensor into top plate notched hole, insert and turn.

9. Twist throttle grip a few times while checking throttle return pulley clearance.

10. De-pin stock gray female connector that was originally connected to map sensor. (Be careful you will be reusing these items)

11. Insert same (3) pins into the A B C port positions located on new female connector attached to new map sensor extension harness provided.

12. Route new map sensor extension harness in convenient manner to reach map sensor located on underside of new bottom mounting plate.

13. Insert extension harness pins into A B C port positions on stock gray female connector from line (10) above, connect female connector to map sensor located on underside of new bottom mounting plate.

14. Install gas tank vent line, electrical harness and main fuel line.

15. Install gas tank bolts and rubber bolt covers.

16. Reinstall seat and side covers.

17. Turn ignition on check for fuel leaks before starting engine.

18. No fuel leaks start engine.

Enjoy your new throttle response and power. Performance Matters

Contributing author to Cycle Solutions
http://www.cyclesolutions.net

Technical research performed on Kingpin Cruisers
http://www.kingpincruisers.net