Bonneville America Forums Forums Technical Forums Performance Mods Air Injection removal...advice needed

Hello guys

I’m considering removing the AI on my 02 America. According to some info I came across on the web this job seems to be straightforward and could be completed by a novice (me) in 30 mins..... Is this as straightforward as it seems?

I’m a little concerned that the chromed section that fits into the top of the cylinder may be gunged up with carbon and may be a little difficult to get out.

Before I decide to tackle the job I thought I’d ask you guy’s for any useful tips to make the task a little easier.

Thanks in advance to anyone that responds to this query.

John

I just ordered the kit from newboneville.com should make the job even easier.

Save your money on the AI kit.
This from the Tech Vault.

Inexpensive AI Removal
Hey folks, just got done removing the noose from around my Beastie's neck, and only cost me about $10 (for 2 M12x1.25 Drain Plugs Part Number 65214, $2.49 each, 1 Tube Copper Anti-seize $2.98, and 1 box generic 3/16" Vacuum Port Plugs Part Number 47391, $1.99, all from Advance Auto, but probably the same at AutoZone or Napa, or any other chain auto parts place) I downloaded the instructions from this site (link below), and made 2 minor mods.
Some tips:
1. Unbolt the Reed Valve after loosening the 2 clamps on the rubber hoses going from the Air Injector tubes to the Reed Valve. Once you take out the two Reed Valve mounting screws, you can slide it forward, and pop it easily out of the ends of the two rubber hoses.
2. I did have to destroy the two compression clamps that hold graphite filled compression fitting (between the short black elbow and chrome injector nozzles) to get the fitting and black elbows off, only because I didn't have a 13mm Open end that would fit down into the opening to loosen them. If you have such a small 13mm open end, then you won't have to do this. Either way, new clamps are very cheap if I want to reinstall later.
3. I cut about 1/4" of the tip of the M12x1.25 drain plugs off (it was just a non-threaded guide section anyway, no threads removed) to make them the same length as the threaded section of the Air Injector Nozzles, just to be on the safe side.
4. Instead of removing the big 3/4" air hose from the Air Intake box to the Reed Valve, I just bent over the last 2", and tie wrapped it shut. Very simple, very effective. If I happen to need to reinstall the system, the hose is still there, or if I stumble across just the right size bung to fill that hole in the airbox, I'll replace the clamped off hose, either way, no one is the wiser from looking at the bike. And the drain plug bolts look like they actually belong, they look like they are fastening the cylinder jugs to the crankcase. Total time to do this was 2 hours 21 minutes, but that included time to run to 2 different parts stores to get the drain plugs (naturally one store was short one on their inventory), run by Wendy's to grab lunch, and babysit my two little boys at the same time!!! So real work time was probably 1 hour easy, and not real challenging at all. Maybe some day I’ll go back an buy the cool bolts with the Union Jack engraved in the head, maybe not. Will post photos. Oh, by the way, why didn't someone tell me this thing had spark plugs, found 'em tucked in behind the AI Injector tubes!!! And all this time, I thought this thing was a diesel!!!! Hmmm!! OH, and I haven't touched the screws yet, that is next, but the popping is almost completely gone, what little I hear is when I stand over the bike with my head next to the end of the pipes, and gun it! Oh, and the instruction (thanks to Jenks!!!!!) were very straightforward, very easy to follow.

I ordered mine from newspeedmaster.com too. It was really pretty easy. I had a little difficulty getting a wrench around the nut at the bottom of the metal post. I ended up cutting it off with a dremel and then slipping a socket (13 mm I think) over the end and it came right off.

Don't remove the AI. It does not affect performance and helps create cool colors on the pipes.

It's a breeze,go for it.

Might be a good idea to keep all the AI parts and pieces, for when the powers that be figure out that motorcycle emissions testing is yet another way to separate us from our paychecks, in the name of what is good, kind, and apple pie for all.

Mine took a voyage to the bottom of the dumpster. Oops.

Thanks to all who responded
The main reason for wanting to remove the AI is to try and reduce the popping I’m getting on deceleration.

I changed my exhausts from TOR’S to Tridents....the popping didn’t really bother me at first but now I’m finding the popping rather annoying.

I’m hoping that by removing the AI the popping will be reduced to a more tolerable level.
Thanks again for the tips.

Me and Al Gore like the air injection system on my 06 America.

When I was setting up my Trident pipes I was trying to figure out what they were equivalent to on the jet calc. And Pat told me to use the Scepter and Bub numbers for my set up with jets and air intake. I'm sure you've thought of this scenario, but if after you remove the AI you still have the popping, might want to check and see if you're not running a little lean, which will lead to the popping too.

I did read something about altering the mixture and changing jets but I’m afraid those modifications /alterations are beyond my current capabilities.
I went to see a bike mechanic and asked for a quote to change the jets, he quoted me £70.00 -100.00 plus the cost of the parts.

As for tweaking the mixture..........I understand you screw something in then screw it out a few turns.
As you’ve probably realised I’m pretty clueless with regard to the workings of engines and carburettors
I have noticed that when I pull the choke out a little the popping seems to be reduced

Nooooo-don't pay a mechanic to do it. You can do this. It's really easy with a little instruction. I just changed all mine in April and will be happy to help you through it.

Ok let's get this straight:
1. I assume you have stock jets and airbox then-right?
2. Do you own a Haynes manual (if not google it and you'll find a cheap one-or there's a free downloadable version on a thread here.)
3. Have you seen this site? http://www.dinqua.com/ It will show you instructions on changing the jets-very detailed.

As far as the AI removal goes. It might make some change in the decel popping. But really the big change is going to be the discoloration of you pipes. And if you have stock jet set up odds are you are lean with after market pipes-especially the Tridents.

You're in the right place for questions and answers. A little confidence and ability to turn a screwdriver and you'll be fine. Besides she'll really run after the changes

Brett

It also raises the engine temperature. The bike can breathe and cool better without it.

Hi Guy’s,

Thanks for all the helpful tips.... and a special thanks to Brett (08 America) for the confidence boost and the link to the Dinqua site.

I’m pleased to say that the AI removal is complete and went without any hitches...I’m actually quite surprised how easy it was to do....maybe there a little mechanic in me after all.

While I had the tank off I decided to change the plugs as the old ones had been in for 8000 mile. They were a little grey in colour and I guess this indicates that the bike is running a little lean. Comments on the attached photo would be appreciated.

The new plugs are the Iridium type. I don’t know if they make much difference to the running of the engine but I suppose I’ll find that out over the next few days.

The next job is the re-jet


Again....many thanks for the help.

John

You're most welcome, John. Glad to hear the AI removal went well. I'm happy to help you out as a lot of people on here have helped me in the past too. Good kharma

I put iridium plugs in and noticed an easier starting, but no change in performance.

Wanna talk jet set up now? What are you thinking on sizes? What airbox are you gonna do? Do you have the baffles in the Tridents?

I'm gonna have my bike dyno'ed in the near future here so I can tell you how good-or bad-my set up is, and you can use me as a learning curve.