Gen 1 AIS Removal question

[Fazerjon]

I've been looking at the various ways people have gone about the complete AIS removal process, and I have all the plastic bungs/plugs for the hoses & air box etc. I bought the removal kit from TPO parts, but when it comes to the outlets above the headers, these need to be completely removed from the head and the plugs supplied pushed down inside the holes, which means once they are in it is non reversible. The Ivan's kit comes with a 5/16-24 tap and bolts. The metric equivalent to that is M8 x 1.25 thread. So at last my question is, has anyone done this using an M8 tap and put M8 capscrews in, instead of 5/16-24?

[Falcon 269]

Yes, and the M8 tap and socket heads actually fit slightly better.  The metric tap cuts easier simply because it is paired to a metric hole.

[Fazerjon]

Superb, thanks for the confirmation Mike  :thumbup

[Falcon 269]

Forgot to add, make sure you use a tapered M8 tap, not the finishing tap.  Just keep cutting until you get 10mm actual clean thread depth - it's all you need.  I have had M8 x 1.25 x 10mm socket heads in mine for over a decade now.

[Fazerjon]

Cheers, will do. One more question, did you use a specially hardened tap?

[Falcon 269]

A tapered M8 HSS tap, yes.

[Cellarman]

Done mine over Christmas piece of cake, got my tap here as I didn't have a tapered one.
Just take your time & use plenty of lube (grease) on the tap, do the two inner pipes 1st as they they are easier the outer two are a bit harder to get to & you need to use a spanner on the tap
Good luck

[Motopsycho87]

I've found you are better off using a thinner oil for tapping (I'm a toolmaker), greases just trap the swarf and mangle the threads of you don't remove and clean them after every few turns. Get a cutting oil for the job

[Cellarman]

I've found you are better off using a thinner oil for tapping (I'm a toolmaker), greases just trap the swarf and mangle the threads of you don't remove and clean them after every few turns. Get a cutting oil for the job

That's why I used grease to catch most of the swarf, but I take your point.

[Fazerjon]

Thanks for your advice people, AIS fully removed today. No probs using M8 tap, I actually had a tin of metal cutting compound, so I kept dipping the tap in that, job done. Went for a test ride after, and all is well apart from a crackling sizzling noise which I've only just noticed when the ignition is switched on. Sounds like something arcing or shorting out, but just been searching the forum and apparently it points to the servo motor. Hope it's that, but not noticed it before.