AIS Removal Instructions Links
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Night Sky Customs VStar AIS Removal
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AIS System, Elbow & Solid Plug Removal
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VStar 1100 & 650
~ Guaranteed no Chirp ~
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Suggested Tools & Methods
- Slide Hammer - Slide Hammer with Adapter so a pair of vise grip pliers may be
attached to the end. Most local auto parts stores will have slide hammer sets that can be rented inexpensively and
most sets will include an adapter so vise grips can be attached to the end.
- Vise Grip Pliers
Removal of Elbows
Before starting make sure that you are working on an over night cold engine. The elbows are a press or
interference fit so the colder the assembly the easier it will be to remove the elbow. Access to the rear cylinder head
elbow is easy. Access to the front cylinder head elbow is a bit more difficult so a towel, rag or other suitable
protective items should be wrapped around the down tube or other areas before proceeding. Attach the vise grips gently but firmly to the elbow and with the slide hammer gradually
increase the amount of force used until the elbow starts to come out.
Sometimes the elbows are a bit more difficult to remove than usual in which case you may wish to use a "freeze spray"
such as freon (if available in your area) or a computer circuit board cleaner such as "Dust Off", when using invert
the can and spray. On the VStar 1100 you may wish to remove the right down tube which is a seperate removable part
of the frame. You will need to remove your seat, tank, right hand floor board assembly and then finally the right
hand down tube - takes a little time but will give you direct access to the front elbow. On the 650 this frame member
is not a separate piece however you may wish to remove the exhaust system, horn, brackets or lines in that area to gain
better access.
Another method is to use the screwdriver & vise grip combination: Clamp the vise grips onto the elbow, insert a
screwdriver or other suitable tool into the elbow and then use a combination of a twisting & pulling motion to remove
the elbow.
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Removal of Solid Plugs
If solid AIS Plugs have been installed then removal is going to be difficult. Best method is to drill a hole in the
center of the plugs keeping as straight an angle as possible making sure to not accidentally drill into the
cylinder head. After drilling a high grade steel self-tapping screw can be inserted or the hole can be tapped
and a regular bolt installed. This will allow a pair of vise grips to be attached and the plugs can be removed with
the vise grip and slide hammer combination. Solid AIS plugs have an approximate depth just under 7/8 inch with a diameter
just under 1/2 inch. Try not to drill past the end of plug because aluminum chips will end up in the exhaust chamber
of your cylinder head. A grade 8 bolt or screw with a diameter of 1/4 or 5/16 inch and a length of at least 2 inches
is a good choice allowing the vise grips to be securely attached.
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Removal of AIS System
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Disclaimer: A certified mechanic should always perform all modifications and installations. If performed
incorrectly you may endanger the safety of you and others and possibly invalidate your manufacturers
warranty. It is the responsibility of the buyer to properly install or to have a certified mechanic
install any product or make modifications for you. Modifying or removing your exhaust or AIS system may
not be legal in some states or countries. Check your local laws before removing or modifying any equipement.
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