:)
The following instructions are not detailed to the extent some would like but they are sufficient enough to get the job done for the vast majority.


KLEEN /AIS removal procedure:

It's a pretty straight forward job using some basic tools once the seat, black side panels (2), gas tank, and both side body panels are removed for easy access to the solenoid, charcoal canister and associated hoses, it does of course require removing the airbox, and that itself requires an interesting method as the airbox is shoehorned into the spars and can be rotated counter clockwise in conjunction with pushing the rubber air intake boots forward making for the necessary room to remove it.

To remove the AIS/KLEEN solenoid, you’ll need the following:
(1) 5/8th vacuum cap (primary solenoid feed from airbox base plate)
(2) 3/8th vacuum caps (or appropriate reed block off plates)

To remove the charcoal canister (and related hardware), you’ll need the following:
(2) 1/8th vacuum caps for throttle body lines.
(1) 3/16th vacuum cap for the red tank inlet located in the upper RH corner of tank when in place (charcoal canister/fuel tank feed – 1/4th caps may be applicable)
(1) suitable hose (reuse the hose with a blue stripe) connected to the blue tank inlet located in the upper RH corner of tank when in place and routed inside the RH frame rail and across the backside of the throttle bodies, then insert a 'T' fitting into it which accepts the OEM tank vent hose and a reused portion of a KLEEN canister hose connected into the other end of the 'T' fitting and run it down alongside the motor so it hangs down below so the tank vents properly.

Band / compression clasps, zip ties, hose clamps throughout (where applicable), are essential in order to seal the vacuum caps.

Heres 1 pic of the charcoal canister and ais pump after removal.

BD

Attached Thumbnails

 

Cool. Thanks for the information, BD. FWIW, Dan Kyle has the block-off plates. They are the same as the 636 plates and under $30. Just got mine in the mail this week, but will install this week.

Yeah the plates are by far the cleanest setup but using the plugs gives the same results so its nice to have a choice.

BD

My doctor said that I'm allowed one stupid question per day, so here's today's question.

What is the AIS / KLEEN? What does it do and why do you remove it?

Are there any ill effects of using the block off plates? The KLEEN system is just an emissions control component, so disabling it won't affect performance or anything, will it?

The plates would be the better setup if you have them or plan to purchase them (at the time they were not available yet so......) The disconnecting of the KLEEN components will not effect performance.

BD

Thanks more usefull info.

have you installed these yet? If so, did they do the trick?

Yep, and yep. :)

A pic for your viewing pleasure:

those look like pics of a pw 50 :P

BD