Author Topic: ais removal (Read 12256 times)

fazer6868 · « **on:** 11 March 2012, 03:14:02 pm »

Hi

my gen 1 has done 132k and have just done the shims and replaced cam chain and tensioner with the help of some mates.

putting it all back together i am trouble with the ais where you clamp the ais pipes to the spigots ( if that is the correct term) by the exhaust pipes.

The jubilee clips are welded to the splayed ends of the pipes and have taken one of the splayed legs with them as in permanent removal of a leg thereby weakening the clamp.

As the ais is apain in the backside i am thinking of removing it but am not sure how you blank off the spigots?

is it done by way of a cover ( from kits that i beleive are sold ) or by tap and die.

if the latter i am not sure i have the skills to do this as no absolutey nothing about this and i am the type of home mechanic that if it can go wrong it will!

So in summary is there something out there which is easy to do rather than too involved and can someone send me a purchase and info link please

The rest of the job i am confident i can do.

Thanks

Falcon 269 · « **Reply #1 on:** 11 March 2012, 06:16:54 pm »

Justy was selling cap kits but has ceased production (no longer working somewhere he can do machining jobs as 'foreigners'

). You can get similar kits from Holeshot Performance in the USA but that will cost you time and money.

If you're not happy with tapping the spigots, cut the original AIS pipes about 2" above the spigot fitting, fold and crimp the pipe and seal with either solder or hi-temp epoxy. To be honest, I suspect the tight crimp alone would be enough to make gas tight.

You'll need to ask a nice member here for a spare spigot fitting to replace the one you've damaged.

Should be plenty gathering dust on garage shelves.

Gray fox · « **Reply #2 on:** 11 March 2012, 06:27:19 pm »

Can't imagine anyone re-fitting an AIS, throw it in the bin, buy an 8mm tap & a small chuck type tap wrench. No drilling required as the holes are ok for tapping. Pop in four 8mm stainless cap screws job done. If i ever see a Fazer with the AIS fitted i assume the valves have never been checked as who on earth would re-fit it?

ghostbiker · « **Reply #3 on:** 11 March 2012, 07:13:36 pm »

I prefer the look of the justy and holeshot kits. But have mine tapped and bolts in them...... Well in 3 of them and the 4th has a broken tap and chem metal in LOL.

It's not to hard to do if you take your time and have the right tap. I did neither and paid the price.

dekker555 · « **Reply #4 on:** 11 March 2012, 07:43:11 pm »

If you do take on tapping those exhaust connections, be absolutely certain that the tap is parallel to that connection when you are starting the tap. It's not that difficult but care is needed. I found a short straight edge to keep laying up the side of the connection, and alongside the tap, to ensure it was in line. Check every quarter of a turn until it's firmly established.

justy1 · « **Reply #5 on:** 11 March 2012, 08:45:48 pm »

ive got 2 kits left. found um when i was emptying my work bench.

justy1000

GrahamB · « **Reply #6 on:** 11 March 2012, 09:21:24 pm »

If you want my advice then snap up one of justy's kits. Tapping a thread in all 4 spigots is NOT as easy as you might think.

fazer6868 · « **Reply #7 on:** 11 March 2012, 09:52:50 pm »

Hi Justy

In laymans terms would you be so kind as to explain what i do so that i can be confident that even a numpty like myself can't cock it up and then i'll have one off you please.

Many thanks

dickturpin · « **Reply #8 on:** 11 March 2012, 09:55:04 pm »

Justy's kit recommended. I fit it about three weeks ago.....fine workmanship Justy!

fazer6868 · « **Reply #9 on:** 11 March 2012, 10:07:34 pm »

Assuming you just place them on top of the spigot/column thingy bit i will have a set please Justy.

Not sure how you do 1 to 1's on here so can you e mail on paulbarber673@hotmail.com with cost and address to send you a cheque please.

Many thanks

Paul

ghostbiker · « **Reply #10 on:** 12 March 2012, 01:14:28 am »

VERY basicly they push on to the spigots and a little grub screw locks them in place. Can't remember if justy's kit comes with the airbox caps or not or if you need to use a little sealent to. But it is a neat finish.

justy1 · « **Reply #11 on:** 12 March 2012, 10:59:47 am »

Quote from: fazer6868 on 11 March 2012, 09:52:50 pm

Hi Justy

In laymans terms would you be so kind as to explain what i do so that i can be confident that even a numpty like myself can't cock it up and then i'll have one off you please.

Many thanks

as mr ghostbiker cant remember

....... its a "complete" kit. the 4 caps plus 1 airbox blanking cap, carb rubber cap & clip. all you need to do is get hold of either

some "generic instant gasket which is rated to 240c" or the stuff below...

http://www.amazon.co.uk/V-tech-Copper-Silicone-Instant-Gasket/dp/B00442ONX0?tag=vglnk-uk-c47-21

click the link below if you want to get some idea of what the kit is.

http://fazer1000.yuku.com/topic/4115/AIS-kit-complete#.T13XRnl8UQo

ill send you an email aswell.

justy1000

dickturpin · « **Reply #12 on:** 12 March 2012, 12:34:06 pm »

FWIW I used the amazon sealant as shown on Justy's link. No problems.
I also took the chance to remove and copperslip the exhaust studs/nuts to avoid any future issues.

D

_PCooper · « **Reply #13 on:** 12 March 2012, 04:19:16 pm »

Just what I'm looking for. Justy you have PM.

eddie · « **Reply #14 on:** 12 March 2012, 05:48:07 pm »

used justy's kit easy peasy..used the amazon v tech sealant no probs

justy1 · « **Reply #15 on:** 12 March 2012, 06:41:20 pm »

cheers mr dicktrpin & mr eddie.

right, i officially have no kits left! mr pcooper you have pm.

justy1000

dickturpin · « **Reply #16 on:** 12 March 2012, 07:02:52 pm »

You're gonna have to make some more Justy....Hae you found an 'under-used' lathe yet?

1967fazer · « **Reply #17 on:** 12 March 2012, 08:12:21 pm »

Damn thats a pity, was one of the next things on my list of "things to do on Fazer as and when I can afford it!". Looks like it'll have to wait a little longer before going down the tap and bodge it path!

_PCooper · « **Reply #18 on:** 15 March 2012, 04:37:15 pm »

Received "the last kit" from Justy this morning, looks like a proper piece of kit, can't wait to get it on the bike. Ordered the sealant that was recommended off eBay and now wishing it had been posted as quickly as the kit was, hope it gets here by Saturday.

Thanks Justy.

justy1 · « **Reply #19 on:** 15 March 2012, 07:59:38 pm »

Quote from: 1967fazer on 12 March 2012, 08:12:21 pm

Damn thats a pity, was one of the next things on my list of "things to do on Fazer as and when I can afford it!". Looks like it'll have to wait a little longer before going down the tap and bodge it path!

sorry, thats it im afraid.

there's these on ebay if that's any help?

http://www.ebay.co.uk/itm/TPO-Yamaha-FZ1-Fazer-2001-2005-AIS-Emissions-Removal-/230628880619?pt=Motorcycles_Parts_Accessories&hash=item35b28d70eb

As for mr pcooper. glad to hear they arrived & that your happy with them. Hope it all goes well when it comes to fitting um.

justy1000

PieEater · « **Reply #20 on:** 15 March 2012, 08:11:01 pm »

If I recall correctly the kit in the link requires the removal of the spigots from the cylinder head which is not an easy job. I can reccomend the holeshot kit but you'll pay as much for postage from the states as you will for the kit, unless a group buy can be arranged.

fazer6868 · « **Reply #21 on:** 17 March 2012, 12:15:36 pm »

Just received justy's kit ( thanks mate ).

Rad is off, ais pipes are off.

carb and air box rubbers look straight forward.

only things i am not 100% certain about are:

where does sealant go ( i am assuming either IN the ais cap that Justy has supplied or ON the spiggot that they fit onto)?
assume you then just push them on and let the sealant seal them?
is loctite 5910 premium black silicone sealant ok which is gasket sealant i bought but never used to do the shims,i.e. cam cover gasket.
assume it is essential that all the wadding ( wire strands assume that are there for heat resistant purposes ), has to come off the spigots first?

Appreciate that these may seem silly questions but i have no expereince of doing this type of thing and would rather be safe than sorry.

Thanks guys

tomjimtom · « **Reply #22 on:** 17 March 2012, 06:04:39 pm »

Hi, I used Justys kit over the winter, all seems fine since

Yes, take the wadding off, the caps won't fit correctly with it on.

I think I put my sealant round the spiggots and pushed the caps on, didn't want to get any excess sealant in the exhaust

push them on and tighten the grub screw

Don't know about the loctite, I used the stuff Justy linked to

solorider · « **Reply #23 on:** 17 March 2012, 06:24:34 pm »

those that have tapped theirs and used a screw i was thinking of tapping mine and cutting the siggots flush to the head,will this work or will there be problems?

PieEater · « **Reply #24 on:** 18 March 2012, 08:48:14 am »

I think you need to explain your idea a bit more, it doesn't sound logical to tap the spigots then cut them off, as mentioned it is possible though allegedly difficult to remove them at which point the kit on ebay would potentially be a neater and simpler idea. Out of interest how are you planning on cutting them?