'05 WR450F AIS removing help

6 replies to this topic
  • MKP

Posted May 10, 2005 - 07:00 AM


New with a '05 WR450F :) , I live in Chile (South America).
I´ve been following the forums and now it's clear to me the benefits of removing AIS.
Considering that here in Chile I don´t have a quick access to an AIS Removal Kit, may I just cut the three hoses that goes to the AIS pump and cap them with a bolt (screw) and clamp ?
Thank you for your advice.

  • Texas4play

Posted May 10, 2005 - 07:43 AM


You can plug the rubber line with a rubber cork and re-connect, yes.

  • MKP

Posted May 10, 2005 - 08:46 AM


I'll do that. :) :D
Sure is the same as taking it all out and filling the holes with the plugs that come with the kit you have in the State.
Thank you :) :D

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  • bigbluejoe

Posted May 10, 2005 - 02:28 PM


I went in on my 'O5 WR and made my own AIS removal kit for the single reason I could not see a picture or find a description of what you get in the kit offered on this website.
Here's what I came up with.
The air box comes with a plug covering the bottom drain.
I removed it and put in on the AIS supply nipple off the top of the air box. I left the air box drain open because I prefer the air box to "self drain". The 1/4" nipple up against the head I plugged with a rubber cap and used the same wire clip. For the air injection nipple (on the head), I put a piece of 3/8" steel rod in my drill press and filed it down until it was about .005" bigger than the ID of the nipple. Heating the nipple up to red, I tapped in the (now frozen) rod. Rather permanent but it ain't comin out or loosening off.

Project cost was about $2.00.

  • MKP

Posted May 11, 2005 - 05:58 AM


OK, bigblue, you have good skills on that :) , I'm not good in mechanics :D .
But please tell me if what I did last nite is OK and wont damage my brand-new bike. :)
1) I disconnected the three rubber hoses from the AIS pump.
2) Removed the AIS pump but left the 3 rubber hoses as is.
3) Took 2 bolts and covered the threaded part with tape to adjust them to the 2 bigger hoses, then plugged them and used the same clamps.
4) Plugged the small rubber hose with a small plastic screw.

Is it OK?

  • bigbluejoe

Posted May 11, 2005 - 06:19 AM


I don't see a problem with your method as long as everything is tied down solid.
Good job!

  • MKP

Posted May 11, 2005 - 06:47 AM


Just to mention that I have problem with warm starting, it doesn´t start unless I put the choke. Also a lot off backfire, and a poor idle.
I did:
- Throttle stop cutting (to 25mm total, and 20 mm of thread, is it OK? :) )
- Baffle removal
- Snorkel out & holes in air box
- Grey Wire
- AIS out

This weekend I'll ride and see how it works before doing more mods (Jetting?).
Thank you.


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