Bikes, Hints'n'Tips > Fazer 1000/FZ1 corner

TPO - AIS Removal Kit

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old son:

I've got one of these kits. You have to remove the stubs in the head just above the exhaust manifold. Has anybody ever removed these stubs and if you have how did you do it and how hard was it?


I know I can put some bolts in and I know I can buy the caps but I want to investigate this first.
Anybody help please?

Falcon 269:
The stubs can be removed by twisting them out with mole grips.  The TPO kit then requires you to drive a ball bearing into the hole to seal it.

Personally, I would go the tap and bolt route. :)

old son:
Hi Mike, the ball bearing is retained in a cap that drops into the head where the stubs used to sit. I don’t think access will be great though.


Can you remind me of the tap and bolt sizes?

Falcon 269:
Ah, I stand corrected, mate. :)  It was many years ago that I last heard of TPO so perhaps their original solution was as I described and they've improved it since then.

M8 HSS tapered tap required.  12mm bolt length but it's not critical.  Go oversize and cut to length if necessary.

old son:
Thanks Mike.

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