ais removal

[fazer6868]

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]

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]

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]

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]

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]

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



justy1000

[GrahamB]

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]

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]

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

[fazer6868]

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]

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]

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  :rollin ....... 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-Si...-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...13XRnl8UQo


ill send you an email aswell.



justy1000

[dickturpin]

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]

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

[eddie]

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

[justy1]

cheers mr dicktrpin & mr eddie.

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



justy1000

[dickturpin]

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

[1967fazer]

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]

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]

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.  :o there's these on ebay if that's any help?


http://www.ebay.co.uk/itm/TPO-Yamaha-FZ1...35b28d70eb



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