Hey Fellas,
I am considering removing my AIS system, and I know that there are posts on this in the tech tips section, but I was wondering if the procedures are same for a 05 model than is is for a 04 model or earlier. Also do I need to buy the AIS removal kit or no. Thanks,
Jet
(White R*'s ride better)

Hey jet

04 and up are 1700's and all use the same procedure. 99 - 03 are 1600's and they all use the same procedure. But the 1600's and the 1700's use different procedures. And if you have a California model you have more crap to take off. Yup, you need to buy a removal kit.

1600 R* require a "plug" to remove the AIS off the heads. 1700 R* need plates. I don't know that you Have to buy a kit to do it, but it makes it a lot easier,and the kits are like 15 bucks.

So, there is a vacuum line that runs from the AIS pump to the back cylinder? Does this line get permanently capped off at the AIS pump, or do you completely remove the line?

You have an 05 right? The entire AIS gets yanked. All of it. Your AIS removal kit will have 2 plates. These cover the holes where the lines attached to the cylinders. Then there is a line that runs back and connects to the top of the manifold. You will get a rubber cap to fit over the nipple on the manifold that the line connected to.

If you don't want to buy the AIS removal kit, you can do it yourself:

- You can probably buy a little cap for the nipple on the manifold at just about any automotive parts outlet, but make sure it seals well or you will spend hours trying to figure out why your bike doesn't run right.

- You can grind the "pipe" portion off the flanges that connect the system to the cylinder heads, cut some type of gasket material to the same shape, and bolt the gasketed "flanges" back into place. Again, I'd use a bit of high temp gasket goop to make sure you have a good seal or you'll have issues. I used a nice, thick copper gasket with a bit of gasket goo to do the trick until my kit arrived. The only reason I got the kit is because the plates are nicely anodised black & I have a midnight roadie.

Take off that AIS, ditch the fuel pump, up-size the float valve and vent the gas cap. Now you'll have a real nice, clean looking bike that runs great ! Put in a jet kit, air filter and do the stage 3 mod to the pipes while you're at it and it'll run REALLY great !

Have Fun !!

Rup <br><br>Post edited by: Ruprect, at: 2007/02/20 21:19

So it is a lot easier to remove the gas tank and the fuel pump, or can you get around this?

jetmechanic wrote:
So it is a lot easier to remove the gas tank and the fuel pump, or can you get around this?

You could probably dink around with the back end of the tank proped up on something while you tried to get the fuel pump bolts out but it will be a lot easier to just yank the tank. It just makes everything easier and pulling it isn't hard. 5 minute job max to take it off. The fuel pump has to come off. No way around that.