ais removal

[PieEater]

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]

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]

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]

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]

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?

[solorider]

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?

i was going to use a dremel,the only reason for cutting them is so the top of the engine looks neater

[PieEater]

In all honesty I only ever see the stubs when I'm on the floor cleaning my bike so looks are not much of an issue, I don't think what you're contemplating is practical but then I still don't understand what you're planning. You could get some domed allen bolts which look neater than a hex headed ones.

[VNA]

Don't cut, just tap.

Make sure you have a good quality taper tap. 

[ghostbiker]

without going out to look, (im a lazzy ass today and still in bed a 11am  ) wouldnt cutting them flush leave the depth to tap a thread a little shallow? wouldnt want the bolt hanging down interupting outflow.
there again as im type this i supose there has to be enough to allow a interfearance fit so it should be enough for a tap.

might be a slightly neater job but if your going to that much extra effort from either a holeshot kit or a simple tap and bolt then the Ebay kit and spiggot removal might be worth going a little further again as it is prob the neatest finish possable.

i went simple tap and cap head bolt, its hard to see it from most angles and dosent look out of place. if i had to do it again i would go holeshot kit though.

[solorider]

those of you that are going the diy route with a tap i bought a m8 taper tap from a local tool supplier made by lyndon,the square end on the tap is 1/4" and a brake adjuster spanner is an ideal fit (mine is a double ended square ring spanner) so hopefully i should have no issues threading the spiggots when i come to tapping them 

[GrahamB]

Good luck with it. I have just done another one yesterday & I will say it again, it's a pain in the ass of a job. 2 & 3, piece of cake, takes minutes but 1 & 4.. .    :'(

[solorider]

Good luck with it. I have just done another one yesterday & I will say it again, it's a pain in the ass of a job. 2 & 3, piece of cake, takes minutes but 1 & 4.. .    :'(

the only one i had a problem with was no 4,the tap i have has a 1/4" square and i have a brake adjuster spanner with a 1/4" end on it,that made it easy to do 3 of them,on no 4 i had to use a 7mm spanner at first,not an ideal size but it did what i needed to do and once i was so dar down i then used the brake spanner to get the tap the rest of the way in

[GrahamB]

Excellent, job well done then.  I think 4 stainless cap head bolts look as neat as anything down there. I had my exhaust off this time around so was able to push swarf down the hole & out the exhaust ports.