Bonneville America Forums Forums Technical Forums Performance Mods Removing the AI

Hi guys, I have been reading everybody's advice re removal of the AI. Can somebody give me a link to explain how to do this (are there any pictures). Thanx

Actually it is pretty easy to do. The kit for the AI removal comes with 2 bolts, 2 crush washers, a small cap which goes on the carb and another larger cap, which goes on the airbox. Remove your tank. The AI is mounted to the frame under the tank. You will see a rubber hose (about 1” round) which leads from the airbox to the AI on the frame. Just pull on the rubber hose on the airbox end and it comes right off. Use the round plug from the AI removal kit and plug the hole where the rubber hose was. There are 2 screws, which hold the AI onto the frame. Unscrew those and the AI will come off the frame. There is a smaller rubber hose, which comes of the AI to the carburetor. Pull the hose off the carb and use the small cap from the kit on the carb to plug up that vacuum port. From the AI you will also see 2 rubber hoses, one leading to each cylinder. Remove those hoses. You will see about a 3” chrome tube where the hose came off. You need to remove that bolt at the bottom of that chrome tube from the engine. The easiest way to get at the bolt (if your not going to put the AI back on) is to take a pair of pliers, grab hold of that tube about 1” above the bolt itself and bend it back in forth until it breaks off. This tube breaks really easy at the point of the bend. This allows you to get a socket in and remove the bolt from the top of the cylinder. Use the crush washer and screw the new bolt from the kit into the same spot. If you intend to ever put the AI back on do not break off the tube. However trying to do it without breaking the tube is a lot more time consuming. I just pulled the AI off another bike for a friend of mine and doing it the above way takes about 15 min.

If you but the kit from Brent (NewSpeedmaster.com), it comes with some great instructions. Takes less than a 1/2 hour to do.

Soren

Yep. Did Brents kit for Nancys TBA. Few steps missing in the instructions.
Remove dash on tank, remove left side panel and faux air filter thingy to plug the air box.
No big deal.
Since I didn't have a wrench or socket handy
to fit the injectors, a quick tap on them with a sharp
chisel broke them loose. By the way the injectors on this
04 were 1/2 inch one side 13 mm the other!?

Very easy job and your pipes will thank you. Wait no longer. Here is a picture of the 'Lil monster you are removing.


Like some others have told me, save those 2 screws, they come in handy to mount other stuff there. I used one of the holes in the frame to zip tie my throttle cables which I moved to the right side instead of the left. (gives more cable slack)

There's a downloadable pdf in the downloads section on this site. Jenks bolts in the UK supply the kit, complete with easy to follow instructions. If I can do it anyone can

Guys
Thanx for the advice - much appreciated. I will keep you posted when I pick up the bike. Thanx again

And.....

Save the corrugated-looking hose and use it to connect your 2 manifolds together, either at the carb fittings or the manifold fittings, doesn't really matter.
It will help smooth out your idle.

Also that lil skinny hose has a restrictor in it. You have to squeeze it out before you can use it. It's on one of the ends, i forget because after I pulled it out I had wished I noted what side it was on. Duhh.
The hose does work well for attaching to the carb bowl drains and draining your carbs before you pull the covers to re-jet etc. (If you leave the carbs on like I do). But it will take all day to drain if you don't take out that restrictor. It's just a little plug looking thing with a pin hole in it.

Georgina - Hey don't think you can't do something on your bike! I bet you would kick half of the men that work on there stuff's butt. Have at it.

:as I protect my nads:

Kewl, your just fine then Ms. Gina.

Gina, you can do it. Honestly the hardest part is lifting the tank off and putting it down carefully so as to not scratch it, and that is only because it's fairly large. Do it on a low tank!! Gas is heavy

I'd better start studying my Haynes Manual on how to take the tank off......

you don't have to take the tank off. you can remove and plug everything and just leave the ai unit mounted where it is. I left mine in there until I had to remove the tank to do something else.
mike

Mike is right. But taking the tank of is easy and a great thing to do now while it's not crucial, that way if you really need to sometime it's no big deal. It's really a 5 minute thing... Just gotta take the seat and console off, the tricky part is pulling it back, then pulling the vent hose off the bottom right, and then getting the tank onto a nice flat surface. Bingo, done. Like I said, go for a ride and drain the tank down Much lighter.

It'll probably get done either at my olds, or at Simons....that 140ish miles from here....ride enough????

The console - taken that off before - the LED for my alarm came off...so I replaced it. For 79p.

I can take the pillion seat off no hassle, but the other one...I'm sure if I take every bolt out it'll come off or the bike'll just collapse into a pile on the floor!

Front seat comes off with one bolt. Super simple. Tank only has one bolt too!

So today I ordered the AI removal kit from Brent...but I don't think it's gonna be put on and the AI taken off till the second week in July. Mainly because that's the next time I'm off and can get to olds/Simons.

But I'll let you know how it goes...