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Cheap AI removal
#147706 04/04/2007 6:58 AM
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Air Injection system is common in many bikes today.

The system is quite simple, a pump suck air from airbox and send to exhaust valve.

The pump works with a membrane ritmic suction from a carburetor hose.

The pump looks like this:

[image]http://img.alibaba.com/photo/50596468/Second_Air_Injection_System.jpg[/image]

AI pump

Lot of people spend money to buy AI remove systems but sometimes this system is useful.
Maybe I find useful in the winter where it permits a faster warm up of the bike.
It's useful in that country where laws oblige to periodical EPA exhaust controls (eg. in Italy after 4 years first time and every 2 years after).

On my bikes insted of removing this system I applied a small spigot or mini ball valve used for air compressed systems.
A valve like this:

[image]http://image.bizrate.co.uk/resize?sq=400&uid=494025466&mid=105838[/image]

Mini ball valve

So I cut the pipe between airbox and air pump and apply this with two screew collars.

I can open and close the valve whenever I need, and I can also partialize, causing only a smaller amount of air go in the exhaust.

There's no consequencies for the pump, only it doesn't suck anything if the valve is closed.

Re: Cheap AI removal
Mechano #147707 04/04/2007 1:31 PM
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that would be awesome when plagued with periodic inspections. how obvious is the valve when it is in place?


mike


2006 neon blue speedmaster
Re: Cheap AI removal
mike57 #147708 04/05/2007 2:50 AM
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Quote:

that would be awesome when plagued with periodic inspections. how obvious is the valve when it is in place?


mike




Oh it's so small.
Just the same diameter of the pipe, maybe the handle, have you seen the photo?

On season change you lift the tank and move the handle to open or close the valve.

Re: Cheap AI removal
Mechano #147709 04/05/2007 5:33 PM
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In my eyes the AI remaval has 2 advantages the first has been covered over and over but the 2nd is that it is much easier to get at your spark plugs with it removed.


I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
Re: Cheap AI removal
The_Dog33 #147710 04/05/2007 5:47 PM
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Much easier than next to impossible you mean?


Benny Black & Silver '02 Too many mods to list Not enough miles ridden
Re: Cheap AI removal
The_Dog33 #147711 04/05/2007 5:57 PM
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Quote:

In my eyes the AI remaval has 2 advantages the first has been covered over and over but the 2nd is that it is much easier to get at your spark plugs with it removed.




What about if you want to remove AI but you're under warranty?
If you don't want to show your mod to you stealer and want advantages from AI removal that's the right way.

And if someone lives in a cold location (mountains, Alaska, Canada), or anyone who want's to use th bike in the winter and profit of the AI to help the bike warm faster.

Here we are not judging the best way doing something, but explaining different ways doing it.

Discovering all of them creates culture, a big amount of lecterature about this bike, mods and tricks.

Everyone can choose what is better for him.

Re: Cheap AI removal
Mechano #147712 04/05/2007 7:08 PM
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I did even cheaper than you, Mechano. I pulled the A/I hose off of the air box, folded the end over and put a tie-wrap on. Disables the A/I, easily reversable, cost 10 cents.


Steelheart- '03 Speedmaster Black/Yellow The Hayabusa Killa 16" Shorties/140 mains/Airbox drilled Procom CDI "There is no cure for Celibacy. But we can treat the symptoms."
Re: Cheap AI removal
BrianT #147713 04/06/2007 3:58 AM
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A friend of mine put a small steel ball (from a broken ball bearing). Another one used a small glass ball.

Re: Cheap AI removal
Mechano #147714 04/08/2007 11:25 AM
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it's starting to sound like time to get out the duct tape.


I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
Re: Cheap AI removal
The_Dog33 #147715 04/08/2007 11:59 AM
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Not sure how much cheaper you can do it for (and do it right) than an AI removal kit.

Soren

Re: Cheap AI removal
BrianT #147716 04/20/2007 3:03 AM
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Quote:

I did even cheaper than you, Mechano. I pulled the A/I hose off of the air box, folded the end over and put a tie-wrap on.



I want to do it this way, at least until I get a manual and can look at putting a valve in, as Mech. suggests (warranty issues)...what do I need to remove the pipe? How is it held on to the airbox and can it be done without removing anything like seat, etc?

Cheers, neill

Re: Cheap AI removal
Echoance #147717 04/20/2007 8:13 PM
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Neil, just grab the hose at the airbox and pull/wiggle. It should pop right off. Fold the last 2" over, tie wrap and Bob's your..., well, you know.


Steelheart- '03 Speedmaster Black/Yellow The Hayabusa Killa 16" Shorties/140 mains/Airbox drilled Procom CDI "There is no cure for Celibacy. But we can treat the symptoms."
Re: Cheap AI removal
BrianT #147718 04/20/2007 9:16 PM
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Oops! I forgot a step. After you pull the hose, cover the hole in the airbox. I used black duct tape. Been holding 3 months now.


Steelheart- '03 Speedmaster Black/Yellow The Hayabusa Killa 16" Shorties/140 mains/Airbox drilled Procom CDI "There is no cure for Celibacy. But we can treat the symptoms."
Re: Cheap AI removal
BrianT #147719 05/01/2007 1:44 PM
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Sorry to bring this up YET AGAIN but I need clarification: does the pipe you refer to enter the airbox at the LH side? (The LH cheese-grater needs to be removed to access it?) Mechano, what size valve did you use?



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