Jstar2 AIS delete How To OK I am done!! Well, done with the AIS delete. It only took an hour a half. So here is my "tutorial" lol I took pics of almost everything I did. I think the only thing I did not take pics of was removing the lower exhaust pipe. The first two pics are of the side of the bike you will be working on the most and where you will begin your first step: -Remove the seat. I assume everyone knows how to do this.
-Remove the access cover to the tool kit
-The cover below the tool kit cover is now off. Unscrew the four "corner" screws. The two top middle ones do not hold the cover in place, so you do not need to remove those.
The air pump (gold cylinder) and the plastic black box it is connected to with the black tube we'll remove that later
The first two pics refer to the AIS tube on the front cylinder.
To get from attached to unattached you just loosen the bronze colored screw bracket and pull the tube away from the elbow.
Pics three and four go to the rear cylinder.
Notice that the small collar is removed with the tube on the rear cylinder. You want to remove this colar on the front elbow to prevent damaging it if it does not come off with the pipe.
Next we are going to remove the tubes completely. First the tube to the front cylinder. You will be removing the bracket in picture two, then disconnect the metal tube from the rubber tube that connects the metal tube and the AIS (forgot a picture or that one, sorry). Congrats! You have just removed the first tube.
The second one is more of a pain, you'll be working on the right side of the bike for this one. Remove the upper exhaust pipe so you have more room. Now, make sure you disconnected the metal tube from the rubber connector and carefully remove it from the right side of the bike. This took me some maneuvering but you just have to keep at it and be patient.
Ok time to remove the AIS. The first pic is of the first bolt you should remove to remove the air pump. The second pic is the two other bolts to remove. Remember to plug the small hose that you removed from the pump with a golf T or whatever you have on hand.
Then remove the black box (don't know what else to call it). It is hooked on, just rotate it towards you and gently pull (sorry, no pic of that either).
Now take off the air pump.
So just a side note, I always put the screws back in the hole they go in so I don't lose them or forget where they go. You can do it if you want, or not, like I said, just a side note
Ok, this next part is removing the elbows, it is going to take a lot of patience and creativity, so just go slow and try not to get frustrated. I used canned air to freeze the elbows, wd40, a hammer, and vice grips. To use the canned air shake it and turn it upside down, then spray it on the elbow, but be careful. DO NOT SPRAY IT ON YOURSELF! (apparently it can cause frostbite)
I sprayed wd40 on the elbow and left it to sink in for a few minutes. Then I tapped it with the hammer and a wooden dowel a few times to rotate it, then I would use a large enough allen key (8MM) to fill the ID of the elbow to loosen the elbow further. Then I would rotate between freezing the elbow and rotating it with the allen key. When it got fairly loose I just kept on pulling with the loop I made with some zip ties (See above). Do this for both elbows. The way you get the elbow out of the front cylinder and the way you get the elbow out of the rear cylinder will be different, they will both take time and a little creativity, but just be patient. If you use the allen key method, the long part of the key will go in the rear cylinder elbow and the small part in the front cylinder elbow. I found this to be the preferred method; less chance of damaging the elbow or scratching the frame (Corsair edit).
Next you plug the holes where the elbows were. I used .45 caliber shells and they work great Remember to clean them before you install them. I used wd40 and a few Q-tips. To install them I just took the hammer and a wooden dowel and hammered them in gently. The front cylinder was a pain to get to though because of the frame. You’re near the end so be patient and take your time doing this I kinda dented the shell, so be careful about that. The pics below are what they look like. After you install those shells just put the covers and seat back on. The last pic is the bike with everything back on (missing the carb cover) and the AIS removed!! YAY!
Thanks everyone for your help with this one
. Hope this tutorial helps out.