Hey Frank, I got the AIS disabled by removing all the hoses that went from the canister to the carb. Everything that was connected under the tank. I have yet to remove the smog pump and the other stuff that is under the rectifier that is for another day. It seems to me that there is a lot more junk on the California Model vs the other state models. When I get the smog pump off, I will post a picture of all the stuff I had to remove. I bought an OEM Service Manual ($60.00) that was much more helpful than the instructions in the tech articles. So I guess it was worth the price. I tried the online manual, and just didn't like it. I prefer to have the book close by where I am working so I can refer to it as needed. Thanks for your advice, support and words of encouragement.

Good for you to continue to work on it and be able to get the job completely done. I know it can look inundating but with pictures and help from here it's not that bad.
We have two CA Stars, an 03 and an 05, both have ported manifolds, rejet kits, and thumbscrew adjustments. Also full pipe systems and many other upgrades we did ourselves. The Ca models have extra smog parts to remove and up to the 03 model only, you have to fight with the elbows pressed into the head. The 04 and up models are just cover plates. New replacement cover plates replace the old with two small bolts, and are a piece of cake to install.
I have alot of free time during the week and if you are close to me at all I would be more than willing to help out.
I'm in the Inland Empire, let me know if Ican help.
Rick

Excellent. The rectifier isn't hard to disconnect and remove, and once you have that out of the way, getting the brackets/pump and switch out of the frame members isn't hard. just a few bolts and some creative twisting and jiggling. They should slide right out to the left, as you look at the bike from the front. Glad to hear that you've made good progress.

just got the ais kit from j&p cycle , easy to install only thing, the instructions came with it said to remove the fuel tank, i didn't , i could get the vacum hose off and the plug back on the manofold without it coming off, with a little help from some long needle nose, and it did help on the sound as i let off the gas at about 65 or 70 it sounded better that with the ais on, i have v&h long shots, i m wondering now if it will sound good with the baffels out , i tried it before i did the ais and it make a sound like a 18 wheeler using a jake brake when i let off the the gas

Yeah... Before removing the AIS, I had a Yamaha Road Fart. Every time I downshifted, "Thpppth thpppth thpppth, brraaaap, brrrrrrrt, plop..."

6hrtbt3,

Whenever I use the online manual, I print out the pages I want... 3-hole punch 'em and put 'em in a binder on the counter in the garage.

Keeps the instructions real close, and if I crumple 'em or get 'em greasy... no big deal!

Liferider1 wrote:
http://roadstarclinic.com/content/view/48/105/

I used this article I just took it further on both sides. Based off of your first pic on this post you still have at least one hose to take off the carb. There is the one on the front left of your picture that gets removed and left open, and there is one on the backside that gets removed also. This one requires a vacuum cap unless your kit came with one. Mine didn't, but I love an excuse to go the the auto parts store.

I cut the hose a few inches from the carb and plugged it - didn't have time to run get a cap.