Well, I got my Hurricane Flow air filter for my 04XL. Just back from a ride and this is a terrific product - not cheap, but I am glad I went first class on this one. The bplinson video about the install is helpful, but if you have an 04 or newer be prepared for some differences both in what the filter assembly looks like as well as the install. I needed to do re-jet as well - with the installation. For you 04-05 owners, here are lessons I learned.
1. Watch the Bplinson video. Read Stevo's jetting primer - twice. Read Malpaso's 04 rejet account on this board. Read the Stickys on this board about jetting. Get the list of part #'s for jets from the sticky on this board. The instructions from NRHS do not come with pictures. I found the bplinson video helpful, the PDF files in the premium section with pictures about rejetting were very helpful.
2. When you buy Hurricaine Flow from NRHS - pay them for jets as well - they were cheaper from NRHS than from dealer. I live close to sea level and NRHS selected jets of 45 Pilot and 190 Main which seem very well suited to my cycle shack slip ons and Hurricane Flow combo.
3. Get all your tools, loctite (blue), copper hitemp silicone gasket maker, jets, etc. before you start. Buy your stainless steel hex bolts to go back in the carb (replacing the brass screws) before you start - you'll need four M4 -16mm for the bottom side of the carb. If you do the top side - needle - you may need other bolts. My hardware store and Lowes did not have the size needed. BoltDepot.com to the rescue. (The postage and handling cost more than the bolts and washers but, they come neatly labelled so you can't screw it up if you read the labels. Yes - I would definetly do business with bolt depot again. It beats the trips to three different hardware stores and two different chains - none of whom had the right stuff. Given what gas costs - BoltDepot is where I would go unless you know your local has got what you want.) I also got some stainless M4 washers for those hex bolts - both flat and lock washers. You may need some PB blaster or liquid wrench of your choice to get some things undone like the carb brass screws. Let PB blaster soak in overnight if anything is recalcitrant to come loose. The tough tool to find is clearly the screwdriver to remove the pilot jet. Slinger airflow works sells one for about $14 or so. I didn't buy it but, wished maybe I had. I bought a 3/16 cabinet tip because someone else on the board said thats what worked for them. It didn't work for me (on the other hand the Craftsman brand I bought did not have the narrow shaft needed, so I eventually found something else that worked. Things called "precision" screwdrivers also have shafts that are no wider than their tips, but most "precision" screwdrivers i could find for sale locally have too small a tip. If I could turn back time this is what I would do - When you buy your new pilot jet - find a screwdriver whose tip fills the slot on the pilot jet, but whose shaft is NO wider than the head of the pilot jet (otherwise it ain't gonna fit in the hole the pilot jet sits down into or the screwdriver is gonna crack the pot metal). Don't start without this screwdriver. If you haven't got a screwdriver that fits, bring the pilot jet with you to the hardware store.
4. Jets are not big - they are easy to lose (don't ask).
5. Customer service at NRHS has been very good. I had left an e-mail and a phone message and got call back from Susan (before I got an email reply) stating they wanted to make sure I knew I wasn't forgotten. Aaron if you are reading this - give Susan a hug for me. Susan thanks for making sure I could ride this weekend.
6. Question - will pre 04 ham cans fit on the 04-05 hurricane air filter?
7. Bplinsons - suggestion about using coppergasket maker to stick the gasket in place on the carb support bracket is brilliant. You need three hands to do this task with out it.
8. thanks to all those on the board whose posts helped me get my re-jet done and the rest of my taxes paid.
9. That rubber molding thingie that seals in between the ham can and the 04 plastic backing plate and square inlet duct - remove it before you put the ham can on the hurricane flow.
10. Butt dyno says there are gains. I acknowledge that butt dyno's are unreliable and often not valid, but this sure does feel good. I did do rejet, cycle shacks, and hurricane flow - so I can not be sure what is hurricane flow and what is the rest of the mods. The candor on Aaron's website about some dyno results adds to my confidence that this is a mod worth doing.
11. you can do all of this with the bike on the jiffy stand. - your wife/girlfriend's yoga mat will make sitting on the ground more comfortable. Do not spill oil, grease, or PB blaster on the yoga mat.
12. check the vacuum connector on top of the carb to make sure it is back on tight. Pushed on mine and idle today seems more stable.
Balpo

6. Question - will pre 04 ham cans fit on the 04-05 hurricane air filter?

Yes but will have a greater gap between the inside of the inner plate and the AC cover, that is you will see more filter.

Another way to have gone is a pre 04 AC cover and the pre 04 kit if you wanted the look of the traditional Hamcan. The filter cover on 04 provides the sealing that the newer AC cover does not provide. The older ones did.

NRHS HurricaneFlow is a great AC. I liked it so much it followed me onto my Dyna glide.

Thanks to the man
with the green eggs and ham.

Another question: mine runs just fine, but idle is a tad unpredictable - not low just unpredictable. Some stop lights it will sit at 1000 rpm, some at 2000 rpm and I can't figure out why. What should I look for?

Spray wd40 around the intake manifold where it connects to the heads and carb first to make sure you dont have any air leaks. If you do, the bikes RPM will change while your spraying.

Also check to make sure your carb is clean(with carb cleaner)and not gummed up in anyway.

Make sure pilot jet is of correct sizing too. Sometimes a too small or large pilot jet can be the cuase of an irregular idle situation. Check to make sure the cables and linkage is clean and moving with no binding etc.

Thanks EC1250R,
I'll try the WD40 trick and see what happens. Need some daylight to do it right (and probably a little spray straw to get a focussed spray), so it ain't gonna happen for a few days. Question - spray the WD 40 on the carb side of the rubber connector or the manifold side or both? I'd assume first one then the other, but figured I should ask.

balpo - Thanks...very informative. Was it a center mount or an off-set AC? I bought the 2" off-set. The Drag Specialties mount that NHRS sent doesn't look strong enough to hold the un-balanced weight of the AC...also, you said use copper gasket maker to hold gasket to this mount...any reason why another type of adhesive would'nt work?

Mine was a center mount. The drag Specialties mount has been fine, so far but I am not a long time user.
The copper enriched silicone gasket maker stuff is a lot like silicone bathtub caulk or RTV sealant - but the copper version is good up to 600 degrees Fahrenheit or maybe more. Bplinson used it for his install and it makes good sense particularly if your read the Trak-Tek install directions about using your third hand. Glueing ( or more accurately tacking) the gaskets in place with the silicone copper gasket stuff in a tube prevents the gasket from sliding out of place and worked well for me. But, the stuff will stink the first time or two you go for a ride.

Hey guys ... just back from a week at the salt flats, pardon me for not seeing or responding to questions.

Glad you're happy with the HurricaneFlow.

Low speed manners should not be a problem at all. Something else is going on.

The gasket we supply with the HurricaneFlow has an adhesive backing. Just peel off the wax paper. No need to glue it in place. Not sure about the gasket included in the DS bracket/breather kit.

We've had no customers report a problem with the bracket or mounting at all. Main thing is, use Loctite blue, because stuff does like to loosen up.

Good luck and thanks for your business.

Hope things went well and fast on the great salt lake bed.
Please thank Susan for her helpful customer service.
For Noobies, or whenever you update the install directions that come with hurricaneFlow it probably would be worth mentioning the self adhesive gasket - I missed that detail and Bplinson video didn't say anything about the gasket being selfadhesive. Likewise, it probably is worth mentioning what to put blue loctite on and what not to put blue loctite on.

Learn from my mistakes: http://xlforum.net/vbportal/forums/showthread.php?t=20497make sure you've got the threads in and out clean.