Hi, I've been working on my bike a lot recently and everything has gone very well. My next thing to do is remove the AIS. I have one fear, well actually two: The elbows seems to be in quite tight. Anyone ever break one off or damage the engine case they are in trying to get them out? Any tips on getting them out easily?

Second question: What if laws around here change and I have to put the AIS back in, is it even possible to get those little plugs back out of the engine?

Just looking for some reassurance.

Yeah I broke the ends off both of mine. I just used vice grips on the ends then went back to pounding them out with the long screwdrive and hammer method. Just take your time and be careful. I did my whole AIS removal in about a half hour.

go to the tech tips section and scroll down to the ais removal
and pick your year of bike. Very good article on how to remove
those little buggers Good detail on the removal.
Just take your time and you'll do ok.<br><br>Post edited by: Greysnake, at: 2007/05/29 17:11

I live in Calif and have the same concerns. Have an '04 with the AIS removed as well as the stock pipes. Rumors abound that the state is going to start smog checks on m/c during reg time. hope not.

I was happily belting mine out using the prescribed 'hammer and big screwdriver' method and succeeded in breaking the elbows off both of mine. Finally solved it by taking an old tent peg, grinding most of the 'hook' off one end until I had just enough of a barb at the end to slot into the hole where the elbow on the AIS fitting used to be. I bent the other end of the tent peg at right angles so I had something to hit with the hammer and gently tapped them the rest of the way out.

EXBCMC wrote:
I live in Calif and have the same concerns. Have an '04 with the AIS removed as well as the stock pipes. Rumors abound that the state is going to start smog checks on m/c during reg time. hope not.

That would be about the time I would start registering my bike out of state somehow. Kind of like the trucking companies do with their equipment to get cheaper insurance.

You guys make me laugh Your stories sound like something that would happen to me.

Since everything has been going so smoothly with all the work I've been doing to my bike, something is bound to go wrong. I think I have made up my mind and I'm going to wait to do the AIS removal until after the riding season!

Even though it sounds easy enough, I just don't like the looks of those elbows stuck into the side of the engine block. Oh well, I'll find something else to tinker with.

Hi there .
I was reading about the smog issuse.
I talked with few of my friends who works for motorcycle dealership and also I read in a paper few months ago...
The statement of smog issuses will enforcement in 2008 bikes with any models which has carb on it, will have a smog checks.. will enforcement 2010 bikes with any model which has EFI . will have smog checks...

thats the last time I heard. But Califorina is just talking but has not been taking any king of action YET.. But wait and see what will happen .
I have 2006 roadie and I am leaving the AIS system on but take it off just the end part of the motor and cap off. When I hear that must have enforcement on 2006 then I will know . But I am more then sure that they will not catch person who own bikes with 2007 and older models. But 2008 to newer. It may happen!!! . Far I know what is happening. If you have any ??? . let me know okay pals .

Hear in Ga, I remember growing up my Dad taking the car to have it inspected and a Safety sticker put on the windshield. It was either a yearly check or 3 years not sure, but that was before the smog devices were on cars...I guess I am an old fart..

jeffgolem wrote:
Hi, I've been working on my bike a lot recently and everything has gone very well. My next thing to do is remove the AIS. I have one fear, well actually two: The elbows seems to be in quite tight. Anyone ever break one off or damage the engine case they are in trying to get them out? Any tips on getting them out easily?

Second question: What if laws around here change and I have to put the AIS back in, is it even possible to get those little plugs back out of the engine?

Just looking for some reassurance.

the biggest pain in the butt of a.i.s. removal is getting the phillips mounting screws off the frame mount plate. yamaha has used for those screws that same strange alloy of steel and cheese that they use for the float bowl screws

if you are worried about removing the elbows, dont.

because of the lack of availability if blanking kits here in europe, i left the elbows and plugged them with 2 m10 cad plated allen bolts stuck in with j.b. weld. not totally tidy, but hey, ya work with what you&acute;ve got!

remove that a.i.s system. it&acute;s a creation of the devil designed to add fugly to the roadie motor