Preparation for AIS
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- Place the plugs in the Freezer overnight, this will shrink the material for an easier install.
- Optional parts removal. Gas tank, left side cover, also you may want to MOVE (It is not necessary to unplug rectifier/regulator from wire harness) the ignition rectifier for easier access to the smog equipment (zip tie the unbolted rectifier out of the way)
- You'll be removing all these smog parts, including elbows and hoses off the bike. 1. Leave the vacuum tube intact, and insert a golf tee into the open end. -OR- 2. Remove the vacuum tube from the manifold vacuum tap, and use some sort of rubber cap to plug the tap. more on this later
Removing the elbows.
Locate the elbow fittings that have hoses connected to them. Disconnect the hoses from the elbows and let them hang until you get the elbows out. (excluding the one from the manifold that will be plugged with a golf tee )
If possible, spray the elbows with Freon. If not possible, grab with vise grips or automotive dent puller and slowly work back and forth until they come out. some people have recommended using screwdriver or wooden dowel along with a hammer to pound the elbow out from the right side of the bike. Personally, I used a 3 foot long, 1" diameter wooden dowel to get the elbows moving... I then used some vise grips to twist them around and finally yank them out... they weren't budging though before I whacked them from the right side of the bike.
Removing the Hoses and Smog Canister.
Finish removing the hoses including the black canister that the other end of the hoses are connected to.
- To install the plugs:
- Cut a one foot long piece of a 1 inch diameter wooden dowel.
- Remove the plugs out of the freezer.
- Push the small end of the plug into the front hole and the back hole with your hand.
- Rest the end of the cut wooden dowel on the plug and hammer the wood until the plug is flush with the cylinder. (easy taps until all the way in)
- Temporarily remove the regulator for easier access to the AIS System.
- Remove the rest of the plumbing and AIS system.
- After all of the smog equipment has been removed, notice there is a tube (vacuum line) that was attached to the black canister. YOU MUST PLUG THAT TUBE WITH A SCREW or GOLF TEE (or your motor will not run properly). Either will work perfect
- Tuck the vacuum line under the gas tank.
- Congratulations! You are finished! Don't forget to reinstall the rectifier if you moved it out of the way.
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This information and procedure is provided
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suitability of this procedure. You assume all risks associated
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SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY
CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.
Any type of modification or service work on your motorcycle should
be performed by a
If performed incorrectly,
this procedure may
endanger the safety of you and others
on your motorcycle and possibly
invalidate your manufacturer’s warranty.
Quote this article on your site | Views: 41740
Written by BruceMill, on 04-24-2012 16:50
still backfiring!!! a lot more
|Success for me too|
Written by Don Dickinson, on 12-30-2011 16:37
I did this today. Took maybe an hour ... most of that time was spent trying to make sure i know exactly what parts were coming out. Using the 1" dowel to hammer the joints out from the right side was key. I had the baron's kit and the plugs went in easily by in using the included aluminum rod and hitting it with a hammer. came close to stripping one of the philips screws, but i figured out a larger head screw driver was needed before it became a big problem. wow that is a lot of stuff that comes out! i am much appreciated for the picture above that shows what you can throw away after doing this.
|AIS cylinder caps .45 casings|
Written by Dishington, on 07-02-2011 16:46
Do I need to fill these casings with something - or can I just install them hollow? 2002 roadstar
|AIS REMOVED FROM A 2001 ROADSTAR|
Written by workharddieproud, on 04-17-2010 22:07
I BOUGHT THE BARRON'S AIS KIT AND USED THESE INSTRUCTION'S AND NOT THE ONE THAT CAME WITH THE KIT. I HAD TROUBLE GETTING THE BACK AND FRONT ELBOW OUT, I WAS ABLE TO TURN THEM BUT, I HAD TO BEND THEM DOWN AND HIT THEM WITH A HAMMER PRETTY HARD TO KEEP BENDING THEM DOWN. ALSO I DID PUT THE TWO PLUG'S THAT CAME WITH THE KIT IN THE FREEZER OVER NIGHT, THE PLUG IN THE BACK I COULD DRIVE IN FAIRLY EASY, BUT THE ONE IN THE FRONT TOOK SOME TIME AND MUSCLE WITH THE USE OF A REGULAR HAMMER, I GUESS I SPENT ABOUT THREE HOUR'S TOTAL, DID NOT HAVE TO REMOVE THE GAS TANK.
|Another successful AIS removal|
Written by White Owl, on 03-27-2010 13:00
Bought the Barons kit. You have to get the fittings rotated to a good angle so when you hit it from the right side you can get the wood right in the welded joint of the fitting. If you hit it too low on the fitting, it will bend. I did not remove the tank but was able to conceal the vacume hose good enough for me. I did get a little nervous when the Barons aluminun bar began to deform on the cupped end and the plugs did not move easily at first. Sooo I got a bigger ball peen and hit a little harder. Sounds good, feels good .
|AIS removal on 2007|
Written by mrklr, on 07-30-2009 19:18
Whats the thoughts on removing AIS on 2007 models ?
|Remove Elbows Quetion|
Written by Allan, on 12-22-2008 12:42
I have read about useing a 1 inch wooden dowel and hammering from the right side. Do you not risk cracking the head with this method? I have been wanting to remove my AIS system, but do not want to end up with any disasters. Also with the above mentioned method,what part of the elbow are you strikeing? thanks,Allan
|Successful AIS removal...|
Written by kdlaz1, on 06-30-2008 13:49
Just did the remocal on my '02n Roadie, and it went easy as can be. Had to use a sawed-off broom handle to tap the elboys out from the right side, but no worries. I used a couple spent .45 ACP casings to plug the holes, and was completely please at how well they fit (and look pretty cool, too).
I was able tog et rid of the "downshift/backpressure chirp" that I had up to now, and it looks cleaner too. Thanks to all for your advice and insight,
Written by fastjohnny, on 09-10-2007 20:16
At 200 rpm & under my 2005 Road Star Siloverado seems to "miss" - at least that's what it sounds like & feels like. Above that rpm I have no problem. Could the AIS be causing this?
Written by narmandt, on 04-21-2007 15:12
I just bought a 2003 Road Star. Previous owner had taken out the AIS system. Plugs are put in. Now there is an annoying chirp every time I decelerate. Sounds like it is coming from the front. I'm thinking that the front plug is leaking. Any thoughts? How would I get the plug out?
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