TPO - AIS Removal Kit

[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.

[VNA]

I tapped em donkeys years ago.  Was fairly straightforward, just took my time.  Don’t use a cheapie tap, make sure it’s a pukka quality hardened item.  You don’t want a snapped tap in there.

Ivan does a kit with a good quality tap, though it’s maybe a wee bit pricey for what it is.
http://www.ivansperformanceproducts.com/R1Airkit.htm

[ZiggyCol]

An even more expensive but very neat non-tapping solution is available here . . .


http://www.holeshot.com/yamaha/fz1/produ...emoval-kit

[old son]

Wasn't somebody on here making these kits some time ago? I think his was similar to the Holeshot kit, no tapping, a cap with a grub screw. Anybody remember who it was, maybe he has some kits left?

[characticus]

I got a set from Justy1 - http://foc-u.co.uk/index.php/topic,512.m...ml#msg2764

Don't think he has logged in here for a few years.

[ram]

i have recently got a small lathe and will be making some soon if you want to wait

[robbo]

Stevegixer had a mate who was making the caps about 3 years ago. Had no luck when I tried to get in touch with him last year, so guess he's not on the forum anymore.

[old son]

Thanks for the update.