Preperation for AIS

• Place the plugs in the Freezer overnight, this will shrink the material for an easier install.
• Optional parts removal. Gas tank, left side cover, also you may want to MOVE (It is not necessary to unplug rectifier/regulator from wire harness) the ignition rectifier for easier access to the smog equipment (zip tie the unbolted rectifier out of the way)
• You'll be removing all these smog parts, including elbows and hoses off the bike. 1. Leave the vacuum tube intact, and insert a golf tee into the open end. -OR- 2. Remove the vacuum tube from the manifold vacuum tap, and use some sort of rubber cap to plug the tap. more on this later

  Removing the elbows.

  Locate the elbow fittings that have hoses connected to them. Disconnect the hoses from the elbows and let them hang until you get the elbows out. (excluding the one from the manifold that will be pluged with a golf tee )

  If possible, spray the elbows with Freon. If not possible, grab with vise grips or automotive dent puller and slowly work back and forth until they come out. some people have recommended using screwdriver or wooden dowel along with a hammer to pound the elbow out from the right side of the bike. Personally, I used a 3 foot long, 1" diameter wooden dowel to get the elbows moving... I then used some vise grips to twist them around and finally yank them out... they weren't budging though before I whacked them from the right side of the bike.

  Removing the Hoses and Smog Canister.

  Finish removing the hoses including the black canister that the other end of the hoses are connected to.

• To install the plugs:
  1. Cut a one foot long piece of a 1 inch diameter wooden dowel.
  2. Remove the plugs out of the freezer.
  3. Push the small end of the plug into the front hole and the back hole with your hand.
  4. Rest the end of the cut wooden dowel on the plug and hammer the wood until the plug is flush with the cylinder. (easy taps until all the way in)
• Temporarily remove the regulator for easier access to the AIS System.
• Remove the rest of the plumbing and AIS system.
• After all of the smog equipment has been removed, notice there is a tube (vacuum line) that was attached to the black canister. YOU MUST PLUG THAT TUBE WITH A SCREW or GOLF TEE (or your motor will not run properly). Either will work perfect
• Tuck the vacuum line under the gas tank.
• Congratulations! You are finished!Don't forget to reinstall the rectifier if you moved it out of the way.

DISCLAIMER: NOPORK.com accepts no responsibility for the accuracy of any information and all information is provided as a reference source. A professional mechanic should always perform all modifications and/or service work. If performed incorrectly, you may endanger the safety of you and others and possibly invalidate your manufacturers warranty.