Zipper's Performance 117-442C User Manual
Installation Instructions for
Zippers Air Cleaner Kits
Max Flow # 117-440, -440B, 440C
High Flow # 117-442, -442B, 442C
List of Materials
(1) Gasket, carb to a/c backplate (1) Thunderbird air filter element 2-1/4”
(2) Air cleaner backplate o-rings (3) Air filter mounting stanchions
(2) Pre-formed breather hoses (3) Torx head cap screws
These kits are designed to be used on Twin Cam® engines equipped with the standard Twin Cam®
“football” air cleaner cover, which makes 360º contact between the cover back and the rubber gasket on
the filter. Do not install decorative cover inserts (due to increased weight) or use 2006-up CVO Touring
model covers that do not make 360º contact between the cover back and the rubber gasket.
(1) Air cleaner backplate (1) Air cleaner inner cover washer
1. Remove existing air cleaner assembly, including backplate. Retain factory supplied
breather/support bolts (2).
2. Place new gasket onto backplate, aligning holes and mounting studs.
3. Install (2) o-rings into counterbores on backplate where backplate meets cylinder head
(a dab of grease will hold them in place during installation). Place backplate over throttle body
or carburetor face with gasket in place. Attach backplate to throttle body or carburetor using
supplied stanchions. Tighten (3) stanchions through backplate into throttle body and tighten to
85-90 inch pounds in a sequence. Due to the thickness of the backplate gasket, perform
several rounds of the tightening as the gasket will crush and relax the torque on the
stanchions. 3-4 tightening rounds should be performed to ensure proper torque.
4. Install (2) factory breather/support bolts through backplate into cylinder heads. Press
pre-formed breather hoses into breather cavities with formed breather tubes aligned with
channels in backplate. Press in deep; even with filter element sealing area.
5. Apply low strength threadlocker such as blue Loctite® to (3) Torx head screws provided
and install filter element to stanchions.
6. Re-install the air cleaner cover bolt through the cover. Dab a small
amount of silicone seal to one side of the supplied thick washer. From
inside the cover, place the supplied washer over the bolt, silicone side
towards air filter element. Apply Loctite on the threads of the bolt and
install the cover assembly onto the air filter element.
This product is legal in California only for racing vehicles which may never be used upon a highway.
Place washer
inside cover
Tips For Cleaning Your Max Flow Filter Element
Gently shake off
and brush away
excess dirt.
Spray on
Cleaning
Solution so that
the filter is fully saturated,
and let soak for 10 minutes.
Rinse filter from the clean
side to the dirty side until
water comes through clear.
Use only low pressure from a
tap or hose.
Allow filter to
dry. A fan may
be used to
speed process.
DO NOT use
heated air blowers,
compressed air, or open
flame.
Make one
careful
application of
Filter Oil to each
filter pleat.
Allow oil to seep
into filter for 20 minutes.
Re-oil any areas that still
appear dry. Do not over oil.
Thank You for Purchasing a Zippers Performance Product!
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