TT AIS Removal Kit Tutorial with Pics


47 replies to this topic
  • kskyles

Posted August 27, 2006 - 09:07 PM

#1

Hi everyone-

I thought a short tutorial on AIS removal would be helpful. This is for the TT AIS kit, NOT THE GYTR kit. I’m sure the GYTR kit is perfectly fine, but I chose the TT kit instead. The kit fit perfectly, and came with very clear instructions.

I am mechanically challenged, so anyone can do this. If I messed something up, please let me know.

Here’s a picture of the AIS

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Remove the seat and battery. Disconnect the battery cables and pull the main fuse holder up off of the clip that holds it in place and move the cables and fuse holder forward. Notice the fitting at the top of the air box.

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Remove the AIS by taking off the brackets, bolts, hose clamps, etc.

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Drain the coolant and remove the right radiator.

Using some pliers, grab the motor fittings and wiggle them out. I cleaned around the holes with some carb cleaner.

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Now it’s time to install the plugs. Here’s a picture of the TT AIS removal kit.

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Apply some high temp RTV under the head of the plugs. Line them up in the two holes and tap them in with a long punch.

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I was a little off-center with my punch, so I scarred the top of the plug by the exhaust.

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Now, I put a little sealant on the edge of the rubber cap for the air box fitting. Just put push it on. It’s a tight fit, but not difficult.

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Now that it’s finished, put your bike back together. Here’s what it looks like without the AIS:

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I hope this helps. Ride hard! Ride safe! :thumbsup:

  • Just_a_trail_rider

Posted August 27, 2006 - 09:14 PM

#2

Excellent. I hope that this becomes a sticky so others can always find it.

  • clark4131

Posted August 27, 2006 - 09:33 PM

#3

It has been stickied and moved to the Performance Index section where it can stay unmolested...SC

  • Lit_Dueler

Posted August 28, 2006 - 03:27 AM

#4

:ride: :applause: WOW!!! That is awesome!!! :applause: :applause: I still have to do this to my bike. Right now I am just getting use to it so I wanted to keep it clamed down a bit. But when I buy this kit, I will have NO problem with it for sure. Thanks a million

Lit_dueler :thumbsup:

  • kskyles

Posted August 28, 2006 - 06:54 AM

#5

thanks for the feedback.

i would feel honored if i had a sticky on TT. i could brag to all my riding friends. :thumbsup:

  • spritefiend

Posted August 28, 2006 - 09:06 AM

#6

hot damn... NICE work..

especially considering the instruction that come with it is only useful if you run outta TP...

John.

  • MSHAM

Posted August 28, 2006 - 09:29 AM

#7

I did this procedure this weekend. Bike runs great. listen to the guys! It's a must for every WR owner.

  • clark4131

Posted August 28, 2006 - 01:53 PM

#8

I stickied the thread so people can peruse it for a while. I also put it in the tech section so it will be there whenever someone may need it down the road. I'll un-sticky it after it gets stale in a couple weeks...SC

  • Oldsmobiler

Posted August 28, 2006 - 04:10 PM

#9

If you are going to tune your carb with the JD jets/needles buy the TT AIS removal kit. If you are going on the cheap buy the GTYR AIS removal kit and use that. After seeing the TT kit I shoulda went that way. I don' t like the plugs or the fact that I'm paying for another needle that I won't be using. :thumbsup: Plus I love how clean the TT kit looks intalled.

Ante

  • seekman

Posted August 28, 2006 - 04:40 PM

#10

I stickied the thread so people can peruse it for a while. I also put it in the tech section so it will be there whenever someone may need it down the road. I'll un-sticky it after it gets stale in a couple weeks...SC


You should include the word "WR450F" in the title otherwise it'll get confusing in the tech section. The AIS removal for the WR250F is much harder for the exhaust side.

Do you have to remove the right side radiator?

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  • 123BigcoopDawg576

Posted August 28, 2006 - 08:41 PM

#11

this is a great thread....i did my bike a couple days ago and this would have been nice to go along with it. i must say you did it just like i did. great job again....now all you need to do is show the bike some love and wash it!!!!

  • kskyles

Posted August 29, 2006 - 05:47 AM

#12

this is a great thread....i did my bike a couple days ago and this would have been nice to go along with it. i must say you did it just like i did. great job again....now all you need to do is show the bike some love and wash it!!!!


it's funny that you say that. my buddies told me the same thing. i took the bike up to southern utah this summer, and had two spectacular mud crashes. i've tried to get all that red dirt off of it, but it's stubborn stuff. no amount of scrubbing, cleaners, or pressure washing will work.

  • thumperwrestler

Posted August 29, 2006 - 05:52 AM

#13

What is an AIS? Do all bikes have them? sorry for the newb question.

  • kskyles

Posted August 29, 2006 - 05:54 AM

#14

You should include the word "WR450F" in the title otherwise it'll get confusing in the tech section. The AIS removal for the WR250F is much harder for the exhaust side.

Do you have to remove the right side radiator?


I'm not sure if you absolutely have to remove it, but it wasn't hard. i chose to remove the radiator because it gives you a lot more space to work with. the fitting above the exhaust was the most difficult to wiggle out, and it made it easier to get the punch on the head of the plug. i also took off the radiator so that i wouldn't damage any of the fins while working.

i think it is the right thing to do, and doesn't add much more time to the job. i'm sure there are guys who've done it without removing it, but they must have smaller hands and much greater dexterity than me. :thumbsup:

like it says in the tutorial - this is my 3rd bike and i'm not much of a mechanic - and i'm always learning.

  • 123BigcoopDawg576

Posted August 29, 2006 - 06:02 AM

#15

to get the exhaust ais part out get two screw drivers, stick on in the angle pipe and start moving the peice side to side it will start to come up as that happens use the other screw driver to help get under the braket and pry it up. took me like 30 seconds to get it out. if you dont feel like taking the rad of just unbolt the screws to it so it will move around alittle bit. get 3 socket extentins and then punch the plug in. other then that its easy as pie!

by the way what do you use for rad fluid. mine came from the dealer a little low and need to add some. thanks

Coop

  • kskyles

Posted August 29, 2006 - 07:06 AM

#16

What is an AIS? Do all bikes have them? sorry for the newb question.


it is the Air Injection System. from what i know, it injects air in to your fuel and exhaust system so the the 2005+ WR models can meet california emissions standards. someone correct me if i'm wrong.

it causes a ton of backfiring and makes your WR difficult to correctly jet.

it's an evil montronsity.

i don't know about other bikes, but the 2005+ WR's have them

  • kskyles

Posted August 29, 2006 - 07:09 AM

#17

to get the exhaust ais part out get two screw drivers, stick on in the angle pipe and start moving the peice side to side it will start to come up as that happens use the other screw driver to help get under the braket and pry it up. took me like 30 seconds to get it out. if you dont feel like taking the rad of just unbolt the screws to it so it will move around alittle bit. get 3 socket extentins and then punch the plug in. other then that its easy as pie!

by the way what do you use for rad fluid. mine came from the dealer a little low and need to add some. thanks

Coop


i flushed my radiators out a couple of months ago when i replaced my impeller shaft. i put engine ice coolant in there.

i'm not sure what your dealer put in there. i just know that you need to be careful not to mix coolant types. to be safe, i'd call your dealer.

by the way, good thinking on the exhaust plug. nice idea.

  • CAVSCOUT96

Posted August 29, 2006 - 07:20 AM

#18

Do ALL 2005+ WRs have AIS or just the ones sold in Kalifornia??

  • kskyles

Posted August 29, 2006 - 07:23 AM

#19

Do ALL 2005+ WRs have AIS or just the ones sold in Kalifornia??


from what i've read, all the US and Canada bikes have them. i think the australia dealers remove them for you. i'm not sure about Europe.

  • seekman

Posted August 29, 2006 - 09:52 AM

#20

to get the exhaust ais part out get two screw drivers, stick on in the angle pipe and start moving the peice side to side it will start to come up as that happens use the other screw driver to help get under the braket and pry it up. took me like 30 seconds to get it out. if you dont feel like taking the rad of just unbolt the screws to it so it will move around alittle bit. get 3 socket extentins and then punch the plug in. other then that its easy as pie!


:applause: You guys with the WR450F's have it easy.

On the WR250F's, you need a slide hammer.

'06 WR250F AIS Removal

That's why the title needs to change in the tech section :thumbsup:




 
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