Bonneville America Forums Forums Technical Forums Performance Mods Air Injection

Exactly what is involved in removing the air injection system in a Bonneville America?

You have to remove the tank. This is really the hardest part, but once you do it the first time you realize how easy it is. Once the tank is off the AI pieces are easy to access. These bits easily unbolt. The instructions that come with the newbonneville.com kit explained it all pretty well. I'm not much of a mechanic and it took me less than an hour. It wouldn't have taken nearly that long had I known what I was doing.

Get the AI removal kit from Brent at newbonneville.com. It comes with instructions.

Tom

the only snag you might fit is having a wrench or socket that will fit over the actual air injectors (those things right beside the spark plugs) that will fit in that narrow valley of the cam covers. Pop out to the garage and see what u got before u get started.

I didn't want to destroy the AI components, so the hardest part for me was removing the clamp from the injector elbow at the metal tube. There's a small tab that's bent over on the clamp that you have to reposition upright with the tip of a narrow screwdriver. Once that's done, the clamp will loosen and you can pull the elbow (with graphite sealing ring) off the tube. Then put your 13mm (?) box-end wrench over the tube and onto the hex head. Loosen that and you're home free.

Now if your bike has more than 11 miles on it, YOUR experience may be entirely different.

Good luck, and let us know how it went.

Well, you guys convinced me to remove mine, so ordered the kit from Brent. Removing the AI was very easy with the instructions that Brent sent with the kit. My manual helped with the fuel tank removal. My bike goes faster now with all the weight of the AI system gone. The only problem was, in the package with the removal kit was a couple pieces of candy. I didn't know where I was suppose to install them so I ate them and now the bike has slowed down to where it was because, at my age, I gained a few pounds of lard from the candy...he he. Thanks Brent. Great service and parts.

Dave

I have a question... In all the times I have seen the topic of AI removal here and elsewhere the only reason I can remember seeing is that so your pipes won't turn blue.
Not trying to be a stick in the mud nor am I exactly what you would call a tree-hugger I figured since it was put there to help with emissions I would just leave it.
Now I've only got a couple of thousand miles on my bike so far but the only blueing I have is about 3/4" out from where the headers connect to the heads. Is this just gonna keep getting worse? I can live with what is there now and plus if I'm doing just a small part to get down on some of the smog here in the big city then I intend to just leave it. Anybody else still have the injectors in place without any significant blueing?

Another reason to keep the AI.... I miss the popping and fuss on deceleration with closed throttle. Yes, I miss it. I removed the AI (Thanks Brent, flawless kit....) but I miss all the fuss when slowing... Guess I'll just have to get some of those pipes that will talk to me... Lusting after the thunderpipes, too old for the really loud ones.....
Ride safe!

There are a couple of reasons besides pipe bluing to get rid of the AI system. It causes a series of muffler explosions on hard deceleration and a muffler can stand to blown up only so many times before it starts losing its internal bits or splits open, usually in the presence of a policeman looking for an excuse to give you a ticket. The other reason is that lighting fires in the pipe is likely to be really bad for the exhaust valves.

Then there are the additional hazards such as burnt personal parts and the chance of starting fires with the overly heated pipes.

Just did the AI Retrofit and it's awesome. Very easy, get a 13mm forsum wrench first and grind one side to loosen the Air injector nuts. Once you have them loose the rest is a piece of cake. I ordered my kit from newbonniville.com. Takes 45 minutes max.

I didn't want to take the AI apart when I did mine, so I took a 13mm pos Harbor Freight box wrench and ground enough out of it to fit over the tube like a line wrench. Worked like a charm.

I just the bought the kit to remove it. Do I need to do any adjustment on the carbs afterwards? The bike runs great. I got the long Triumph pipes on it.

Found a old thread that discussed this. Sorry about doubling up.