I really need to get out of the house
Join Date: Dec 2003
How To remove KLEEN / AIS for Cal / 50st bikes
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 (throttle body lines)
(1) 3/16th vacuum cap for the red tank inlet (charcoal canister/fuel tank feed – 1/4th caps may be applicable)
(1) suitable hose (perferably the hose with a blue stripe) connected to the blue tank inlet nipple and routed inside the RH frame rail and across the backside of the throttle bodies, then insert a 'T' fitting into it so that the OEM tank vent hose & overflow hose can be connected into the other 2 ends of the 'T' fitting so the tank vents properly.
Band / compression clasps, zip ties, hose clamps throughout (where applicable), are essential in order to seal the vacuum caps.
Those who stir the shit pot should have to lick the spoon.
Last edited by Big Daddy; 01-23-2006 at 08:05 AM.