RoadStar AIS System Removal & Kit Installation Instructions
RoadStar 1600 & 1700
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Removal of AIS System
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Removal of the AIS assembly includes only a few components & tubes that are unbolted or unclamped from your bike.
This involves simply removing your smog pump assembly located between your engine and down tubes, the air injection
tubing and lines running from your smog pump assembly to each of your cylinder heads and the injector elbows or
flanges at the cylinder head.
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Remove Smog Pump Assembly
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- Remove the regulator/rectifier by removing the two bolts holding it in place and disconnecting the wiring harness
- Unclamp and disconnect the hoses leading to the ais injector lines from the reed valve
- Disconnect the vacuum line at the air cut valve
- Remove the 3 pump assembly to air filter bolts and remove the air filter
- Remove the 3 pump assembly to frame mounting screws and remove the remaining smog pump assembly
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Remove Vacuum Line from Intake Manifold to Pump Assembly
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To remove the vacuum line and directly access the intake manifold vacuum port so that it may be plugged
the tank should be removed.
- To remove your tank first release and remove your seat.
- Next remove the instrument cluster by first removing the 3 bolts holding it in place. Then carefully lift
the instrument cluster part way up off the bike. Underneath there are connectors that need to be disconnected
before the cluster can be completely removed.
- Disconnect the fuel tank vent line.
- Disconnect the fuel line at the petcock making sure the petcock is in the off position. Before unclamping the
line make sure that you have rags or a small bowl handy to catch the fuel that will leak out of the line when you
disconnect it.
- Unplug the small connector that leads to the tank.
- Remove the tank mounting bolt and slide it out.
- Gently pull tank back a few inches and then lift up & off to remove.
- Remove the intake manifold to smog pump assembly vacuum line and cap the port.
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Remove Air Injector Flanges 2004-2007 RoadStars
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The front injector is readily accessible and can be simply unbolted and removed. The rear
cylinder injector is behind the fuel pump assembly so you will need to remove your fuel pump & cover.
When removing the cover first remove the 2 screws located on the bottom of the cover then
lift up on the cover to free the catch on the top of the cover and then pull out & away. Next
disconnect the fuel pump power connector and the fuel line to carburetor - there is fuel in the line so have
rags or bowl handy to catch it. Finally remove the two bracket bolts and then the fuel pump assembly.
You now
have direct access to the rear injector, unbolt and remove.
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Remove Air Injector Elbows 1999-2003 RoadStars
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The fuel pump assembly does not need to be removed to access the rear cylinder injector elbow. However,
you may wish to remove the left hand side cover for direct access to the elbow. To remove the
side cover simply remove the cover bolt and pull out. Before starting to pull the elbows out 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 elbows. 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.
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Suggested Tools & Methods
- Slide Hammer & Vise Grip Pliers - Slide Hammer with Adapter so 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.
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Direct Pull Method - Slide Hammer & Vise Grip
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.
Twist & Pull Method - Vise Grip & Screwdriver
Another method is to use the screwdriver & vise grip combination: Clamp the vise grips securely onto the elbow,
insert a screw driver 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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Installation of Plugs or Port Covers
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Solid Plug Installation for 1999-2003 RoadStars
Push the plug into port and tap in until seated using any suitable tool. You may wish to freeze the plugs over
night, use a freeze spray or other method to make the plugs as cold as possible for easier installation.
AIS Cover Installation for 2004-2007 RoadStars
Install your new cover plates using original gaskets and bolts. When installing the bolts use a thread locker
such as loctite blue on the threads and gently tighten until snug do not over tighten - better to use a little
thread locker.
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Installation of Plugs or Port Covers Finished
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Reinstall Tank, Seat, Side Cover, Fuel Pump Assembly & Rectifier
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