Road Star Clinic - 04 Road Star AIS Removal

04 Road Star AIS Removal

Written by Barron Cumming (red350SS)

Friday, 11 June 2004

Supplemental Instructions for NoPork's and Paul Yotsuya's Articles

EDITOR's NOTE: Rather than write an entirely new article on AIS removal for the 04's, Barron chose to write an article outlining the differences between the 99-03s and the 04s, to be used as a supplement to NoPork.com's AIS removal article. The same should apply to California models as well. For California models refer to the article written by Paul Yotsuya about removal of the California specific AIS, and use this article as a supplement.

The 04 Road Star AIS system is similar to the earlier models, the biggest difference being changes made in the way the pipes fasten to the cylinder heads. Both pipes (front and rear) now use a bolted on flange, similar to a small exhaust flange. The Location for these hoses is in the front of the front cylinder and the front of the rear cylinder.

You can remove the AIS without removing the gas tank by either plugging the vacuum line that runs from the pump to the top of rear cylinder at either the original pump location (plug with golf tee) or by completely removing the line from the motor, and plugging its port on head with a vacuum cap (refer to other articles for more detail).

To remove the AIS pump, follow the NOPORK instructions for the AIS removal on 03 and earlier (Paul Yotsuya for California models). The pump is in the same location, and mounts the same. However, ignore the instructions pertaining to the elbows and plugs in the heads. On 04's you will have to remove the fuel pump cover and fuel pump to gain access to the rear AIS tube entry point, and also unbolt 2 bolts holding the rear AIS tube to the bottom of the cylinders.

Now, simply unbolt the 2 bolts from both front and rear flanges, and remove the stock tubes. Be sure and save the metal gaskets behind them. You will have 2 block off plates in your AIS removal kit. Put the original gaskets on, and bolt the plates over the holes in the head. Tighten bolts and you are done. Be sure to replace the fuel pump and cover, and you are ready to go.

Good Luck, Hope this helps.

Barron

Questions should be asked in our forum (Use discuss link below). The forum is very active and you stand a good chance of getting your questions answered there. If you would like to leave feedback for the author, or have additional information you think will benefit others, please use the comment section at the bottom of this page.

Discuss this article on the forums. (15 posts)

DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only. Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure. You assume all risks associated with the use of this information. NEITHER THE PUBLISHERs NOR THE AUTHORs 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 always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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Comments (8)

Royal Star AIS
Written by Rollin15733, on 07-17-2008 22:57
I have had my 05 Roayl Star TD in the shop twice for the backfire. Been re-jetted/adjusted and still does it (Baron pipes). I cant find any instructions on how to plug the AIS on this bike. Please help! Mike

Question on the "plugs" neede for the
Written by kdlaz1, on 06-25-2008 01:21
I read thru the procedure on NoPork.com's site for my '02, and the process looks and sounds super straight-forward. I'm planning on doing it to see if it will eliminate the whistle I get when I down-shift, or coast against the motor's compression.

My question is this: What size/type of plugs do I need to get to fill the holes? How do I be sure that I don't seat them too far into the cylinders and interfere with the pistons?

I hope these aren't silly questions, but I'd HATE to screw something up on a modification that seems so bsic.

Thanks,
Kimball

SO.........
Written by vwtech0, on 06-05-2008 20:00
What are some cool things we can do with the parts?

Done on 07
Written by MS1700, on 05-14-2008 15:10
I ordered a kit on E Bay for like $14 to do this, It was just the plugs and a Intake cap but was worth it as it also contained printed instructions to refer to. Everything goes as it is printed here. The engine runs much smoother and quieter and I am glad I did this AIS removal. All removed parts can be re-installed anytime. (But Why?) I added LED lights while I had the Tank off, took my time and was all done in 3 hours. Great thing to do to your Roadstar!

Californian Roadstar
Written by FauxRider, on 04-24-2007 18:35
I have done AIS removal.Do I remove the charcoal canister that is just below the front horn? Do I cap off hoses?

AIS Open Ports
Written by Steef, on 08-20-2006 10:12
Have a 05 Roadie and was backfiring and idle was rough to say the least!!!
Bought a vacuum cap and plugged the open port as per your instructions... Problem solved...

Thanks :grin

AIS, What's chirping?
Written by StarMyram, on 06-22-2006 20:16
I used to have an 04 V-Star 650 Classic and it made a funny noise while coasting on highway and cruising in town at low rpm.
Just got a brand new 05 Roadstar Silverado ...Ya know, this bike is beautiful, torquey, and a nice low "bump,bump,bump" exhaust tone at low rpm. But for crying out loud, WHAT is this annoying chirpy sound?! This bike has it even worse than the V-star!

Well, the other night I was fumbling around the running engine with my fingers and eneded up with my finger in the air intake tube hanging down off the AIS pump. The chirping stopped! HA! Found thee source of the noise! Did some research as to where these little pipes went to and fro on the AIS. I decided I could do without the peice of crap on my bike. (don't tell Kyoto! :grin

)
I got out my tools and removed the AIS pump and it's filter and all the brackets. Removed the vaccuum pulse line from the intake manifold and put a cap on the tee. I left the chrome tubes attatched to the heads, I used the one left over hose (pushed a 1" long wooden dowel into the hose to seal it off to avoid exhaust gas travelling from one cylinder port to the other through the chrome lines and burning up the hose) and installed the hose to each chrome line.
After admiring the new clean, uncluttered look of the front of the engine without AIS, I started the engine and admired the clean V-twin engine sound, with a nice clean exhaust tone with no "fluffing" from the tailpipes (the way it should be.) I took the bike for a ride and Voila! No more chirping sound! Yeah Baby!
I understand Californians have emmission laws and lots more tubing on the bikes for charcoal canisters and such so I don't know about thse bikes. Removal of the AIS system is not necessary for performance gains since the AIS does not rob power or performance. But it's just plain ugly to look at, and it annoyed me to no end because of the crappy sound it adds to the engine. Here in Alberta, I can get rid of it without some emmissions police hassling me too. I plan to make steel plates to cover the ports in the heads and remove the chrome tubes completely when I get time this coming winter.

'05 AIS Removal
Written by BadHabits, on 02-18-2006 13:05
I've not seen anything on the AIS removal of my '05 R*. Is this required?

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