The World According to Zuki Dude
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Zuki Dude’s M50 How To
for the Thunder Mfg. Air Filter Kit
Welcome to my How-To instructional supplement for the Thunder Mfg. Air Filter Kit as installed on the
2005 Suzuki M50. This step-by-step procedure also applies to the Volusia 800. I have made every
attempt to cover the full installation with what I feel are helpful pictures and tips. Please note I am not a
licensed mechanic; only a serious enthusiast with tons of mechanical experience. As such, you the
installer and/or installee assume all risk and liability associated with these instructions, installation,
safety and state laws where applicable. In other words, you agree to not hold me liable for damages in
any way, shape or form to your bike or person for your own neglect and/or stupidity. Let’s begin.
NOTE: This procedure involves removal of the fuel tank. Please use all precautionary measures
when handling flammable liquids. If you are uncomfortable or feel mechanically inept, please
seek a professional's assistance. Also, Thunder Manufacturing recommends this unit be installed
on bikes with aftermarket exhaust pipes only and some sort of air/fuel controller such as the
DynoJet's Power Commander.
Tools Needed:
Clean work space
Latex/Nitronal Gloves
4.0 Metric Hex Key
5.0 Metric Hex Key
6.0 Metric Hex Key
1/8 Inch Hex Key
Socket Wrench
10mm Socket
Pliers or Vice Grips
Thunder Manufacturing includes these items with their Kuryakyn Hypercharger Adapter Kit:
http://www.zuki-dude.net/hypercharger-how-to.htm
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The M50 will not be utilizing these parts from the kit:
Seat and Fuel Tank Removal:
1. Begin by removing the passenger and main seats using the 6.0 hex wrench. Place seats
somewhere out of your working area so as to prevent damage.
2. Remove the chrome center gauge cluster on top of the fuel tank by unscrewing the three hex
bolts. Next unscrew the gauge panel from the bezel using a Phillips head screwdriver. Place the
chrome bezel somewhere out of your working area so as to prevent damage. Tip: Remove the left
side steering neck decorative panel by pulling upward and outward to release the plastic
connectors. This will allow the gauge panel to dangle freely without scratching the cover or tank
finish. You may want to wrap the gauge panel in a washcloth or soft rag to further reduce the risk
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of damage.
3. Remove the rear hex bolt holding the fuel tank to the body using the 6.0 hex wrench.
4. Slide the fuel tank toward the rear about 2 inches to remove from the front mounting bushings and
lift upwards. Tip: It is very useful to have assistance in this procedure (or the one stated in the
last "tip" as one person can hold the tank while the other unclips the fuel line, fuel pump and
center bezel connectors.
5. Unclip the fuel line from the tank. Tip: It is best to perform this task on a near empty tank.
However, you can place a rag under the tank so as any fuel leakage from the removal of the line
can be absorbed. If you are doing this step by yourself, you can use the mini vice grips to hold the
gray area of the plug while pulling off the clip if it seems too tight by hand.
6. Unclip the electrical plugs and place the fuel tank somewhere out of your working area so as to
prevent damage.
Stock Air Intake Removal:
7. Start by removing the two 4.0mm hex bolts holding the intake box to the engine. You will not
need to reuse these.
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8. Next unscrew the clamp holding the intake box to the intake pipe by lifting the box outward from
the bottom to gain access to the clamp's screw.
9. Unclamp the 1/2" P.A.I.R. hose and the air temp sensor from the backside of the air intake box
and unscrew the sensor from the box. Place the box out of the work area so as to prevent damage
from the backside of the intake box. Tip: Sell it on eBay!! Why not? You won't use it again,
right?? Retain the air temp sensor for use with the Hypercharger!
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10. Remove the three 10mm bolts holding the stock air intake brackets to the cylinders. The bracket
and bolts are no longer needed.
11. Plug the P.A.I.R. hose either from the intake side (shown above), or follow the next three steps.
Tip: The hose plug supplied with Thunder's kit is for a 5/8" tube and will not work with the M50's
1/2" tube. You can use either a properly fitted tubing plug, or a threaded bolt large enough to fit
snuggly into the tube, or follow the next step. I do not cover the P.A.I.R. valve removal process in
this how-to procedure.
12. Remove the chrome P.A.I.R. valve cover from the left side of the engine by unscrewing the two
10mm nuts.
13. Unclip the 1/2" hose from the front of the valve and remove the hose from the bike.
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14. Plug the front port of the P.A.I.R. valve. Tip: I used the red plastic hose plug supplied with the
Thunder kit by reversing it onto a cut portion of 1/2" hose and clamped them on as shown in the
following pic. Reinstall the chrome cover.
Hypercharger Air Intake Kit Installation:
15. Install the stock air temp sensor to the rear of the Thunder intake adapter using the supplied
5.0mm socket head cap screw. Tip: My pic below shows the stock Phillips screw ... use Thunder's
supplied screw.
16. Plug the harness back into the air temp sensor.
17. Install the adapter plate to where the stock air intake upper two bolts were located using the
supplied spacers (see below pic). Be sure to insert the upper opening into the stock plastic air
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intake duct. Secure adapter plate with the supplied 5.0mm chrome button head hex bolts. Tighten
the screw on the intake duct ensuring the clamp is fully seated.
18. Install the Hypercharger backing plate to the Thunder adapter being sure to orient as shown in the
below pic. Secure with the two supplied 4.0mm tapered head hex bolts.
19. NOTE: I am including this step as a tip whereas it was excluded from the Thunder Mfg.
instructions. However, I brought this to their attention and the following is what I recommend.
Looking at the top of the bike where the fuel tank was removed, locate the gray/red striped
vacuum hose on the right side of the intake duct. Cut through and insert the T-fitting supplied
with the Thunder kit. The bottom port of the T-fitting should be in the downward position. This
vacuum modification is required in order for the butterfly doors on the Hypercharger to function
properly. Tip: Prior to installing the T-fitting, install the supplied vacuum hose to the middle port
of the T-fitting. The fitment of the hoses will be tight; I recommend a touch of all purpose liquid
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lube such as WD-40 to assist with the fit.
20. Remove the circular side panel of the Hypercharger using the 1/8" hex key on the 4 hex bolts.
21. Install the Hypercharger to the Thunder backing plate using the three supplied 4.0mm hex bolts.
Reinstall the side panel.
22. Drop and loop the vacuum hose you installed on the T-fitting downward and up to the
Hypercharger's butterfly actuator.
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23. Ensure all hoses, bolts and electrical connections are secured.
24. Re-map your fuel computer accordingly.
25. Reinstall the fuel tank, gauge bezel and seat.
26. Start and enjoy the new performance and look of your M50!!
Reference: Check out the difference between the M50's stock intake shown below and the
Hypercharger intake shown above. Wow ... right?
http://www.zuki-dude.net/hypercharger-how-to.htm
2/4/2006