TT AIS Removal Kit Tutorial with Pics


47 replies to this topic
  • darrylwt

Posted September 05, 2006 - 08:19 AM

#21

Do you really get that much out of putting on the AIS removal kit??? I was told by the dealer you don't get that much from removing the AIS and if you leave it on it looks good when the Ranger shows up but then again I live in Calif. So far I have done most the mods such as Gray Wire. throttle stop, White Brothers E2 muffler and a RTT Stabilizer Triple Clamp. The Air box I am not sure yet the carburetor can only handle so much air I think the box is big enough to handle the air the carburetor needs???? :thumbsup:

  • kskyles

Posted September 05, 2006 - 02:16 PM

#22

Do you really get that much out of putting on the AIS removal kit??? I was told by the dealer you don't get that much from removing the AIS and if you leave it on it looks good when the Ranger shows up but then again I live in Calif. So far I have done most the mods such as Gray Wire. throttle stop, White Brothers E2 muffler and a RTT Stabilizer Triple Clamp. The Air box I am not sure yet the carburetor can only handle so much air I think the box is big enough to handle the air the carburetor needs???? :thumbsup:


you'll see through most of the AIS posts that performance is not increased. i have noticed that immediately, all backfiring is gone. my bike is now much, much easier to jet. most of all, i'm rid of all that unnecessary tubing and junk around the engine which makes it easier to get to the carb. it also looks much cleaner.

i like ridding my bike of unnecessary junk like the AIS.

  • darrylwt

Posted September 07, 2006 - 11:38 AM

#23

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

http://i41.photobuck...IS/P1010044.jpg

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.

http://i41.photobuck...IS/P1010045.jpg

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

http://i41.photobuck...IS/P1010046.jpg
http://i41.photobuck...IS/P1010047.jpg
http://i41.photobuck...IS/P1010050.jpg
http://i41.photobuck...IS/P1010049.jpg
http://i41.photobuck...IS/P1010048.jpg

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.

http://i41.photobuck...IS/P1010059.jpg
http://i41.photobuck...IS/P1010052.jpg
http://i41.photobuck...IS/P1010053.jpg
http://i41.photobuck...IS/P1010059.jpg

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

http://i41.photobuck...IS/P1010051.jpg

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.

http://i41.photobuck...IS/P1010054.jpg
http://i41.photobuck...IS/P1010055.jpg
http://i41.photobuck...IS/P1010061.jpg

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

http://i41.photobuck...IS/P1010060.jpg

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.

http://i41.photobuck...IS/P1010056.jpg
http://i41.photobuck...IS/P1010057.jpg
http://i41.photobuck...IS/P1010058.jpg

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

http://i41.photobuck...IS/P1010062.jpg
http://i41.photobuck...IS/P1010063.jpg

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


Do you notice that your bike runs cooler or hoter with the AIS removed????

  • kskyles

Posted September 07, 2006 - 02:17 PM

#24

Do you notice that your bike runs cooler or hoter with the AIS removed????


i rejetted it when i did the AIS removal and noticed that it runs a little cooler. since i did the two steps together, the two factors are confounded, so i can't state which one it was with any confidence. i'm fairly certain that the jetting is the reason for the cooler running bike.

  • darrylwt

Posted September 08, 2006 - 10:16 AM

#25

i rejetted it when i did the AIS removal and noticed that it runs a little cooler. since i did the two steps together, the two factors are confounded, so i can't state which one it was with any confidence. i'm fairly certain that the jetting is the reason for the cooler running bike.


I agree with you I think the jetting did more for the cooling as we all know fuel is a cooling agent. I will probably remove the AIS but right now I have the E2 muffler I need to get jetted and running right and try out the RTT Triple Clamp and go from there It all takes time to get all the tweaking done.

  • Thom_McNabb

Posted December 04, 2006 - 12:27 PM

#26

Question:

I like my jetting just fine, if I remove the AIS do I need to re-jet if my 450 works fine now?

  • clark4131

Posted December 04, 2006 - 01:27 PM

#27

No...SC

  • Thom_McNabb

Posted December 04, 2006 - 02:17 PM

#28

SC You have lots of WR knowledge, so here is a question for you...

I have heard of folks having lots of issues jetting and having to change jetting often relative to altitude and riding conditions etc.

My experience has been that after some initial fiddling my 450 never stalls or stumbles down low and is pretty cleanly jetted for every where I go. I have ridden in thunderstorms in the Sequoias, hot days of trail work in the Piutes, desert raced, and done dual sporting below sea level in Death Valley. Only in Death Valley did the jetting seem too far on the lean side, other times it ranges from slightly lean to perfect.

SO here is the question am I
A) Lucky
:worthy: Not Picky enough to notice
or
C) Does the AIS has some beneficial effect on stabilizing jetting?

  • Seabass

Posted December 04, 2006 - 03:14 PM

#29

SC You have lots of WR knowledge, so here is a question for you...

I have heard of folks having lots of issues jetting and having to change jetting often relative to altitude and riding conditions etc.

My experience has been that after some initial fiddling my 450 never stalls or stumbles down low and is pretty cleanly jetted for every where I go. I have ridden in thunderstorms in the Sequoias, hot days of trail work in the Piutes, desert raced, and done dual sporting below sea level in Death Valley. Only in Death Valley did the jetting seem too far on the lean side, other times it ranges from slightly lean to perfect.

SO here is the question am I
A) Lucky
:worthy: Not Picky enough to notice
or
C) Does the AIS has some beneficial effect on stabilizing jetting?


I'm the same way...once I got my bike dialed in it seems to work just fine everywhere.

  • clark4131

Posted December 04, 2006 - 04:33 PM

#30

On my '05, all I really do is change out the needle when the temp changes and I get 100-degree changes throughout the year. I may need a twist one way or the other on the fuel screw, but that's it. Once I got my AP dialed in, all my problems went away as the off idle bog is the biggest issue these bikes have. The AIS removal helps you dial it in, but only because the decel popping caused by it is eliminated leaving just the jettin to cause it. Since the AIS comes into play in the exhaust, it doesn't effect the pre-ignited air/fuel mixture. So to answer all your questions...it's likely a combination of the first two and no on the third...SC

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  • sefto

Posted December 04, 2006 - 09:58 PM

#31

06 Aussie bikes dont have the AIS

  • Roostmeifucan

Posted April 09, 2008 - 08:24 PM

#32

where do i find the TT ais removal kit on the online parts store?

  • KennyMc

Posted April 10, 2008 - 06:51 AM

#33

where do i find the TT ais removal kit on the online parts store?


Well, you could try this...:thumbsup:

http://shop.thumpert...talk_aissrk.htm

  • cyclingsucks

Posted April 15, 2008 - 07:53 AM

#34

I can't seem to find any info on removal of the AIS for an 08 wr450f--any ideas? Can i basically just follow the instructions for an older bike?

  • KennyMc

Posted April 15, 2008 - 08:14 AM

#35

I can't seem to find any info on removal of the AIS for an 08 wr450f--any ideas? Can i basically just follow the instructions for an older bike?


Yeah, just follow the instructions for the 07. They are the same.

  • mach1jonny

Posted June 16, 2008 - 08:00 PM

#36

Great tutorial - Has anyone just tried to block the AIS instaed of removing it. The closest place for me to ride is Prairie City, only 10 min away from home. I can usually get 1-2 hrs. after work. However they do check for the AIS.

  • kskyles

Posted June 17, 2008 - 10:38 AM

#37

theres been a few posts in this forum, and the CRFx forum about blocking of the AIS with JB Weld. Seems like a perfectly good alternative than removal. you could probably find it with the search function.

  • panaman

Posted August 17, 2009 - 07:36 AM

#38

Looks like TT doesn't sell the AIS removal kit anymore

  • SAWR450BOY

Posted January 06, 2014 - 09:03 AM

#39

Anyone still making the TT AIS removal kit?



  • DeepPurplishBlue

Posted January 06, 2014 - 10:11 AM

#40

Anyone still making the TT AIS removal kit?

 

 

http://www.thumperta...50-ais-removal/






 
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