Forum Donations
Search
VTF Google Search
 Click Here

AIS Removal

  • Advertisement

Post a reply

AIS Removal

PostAuthor: gruuvinrob » Tue May 15, 2018 3:46 pm

Getting to the XV250 in a moment, I own a V Star 1100, and have enjoyed a lot of modifications on it over the last 15 years.
When changing pipes and air intake to a much freer flowing system, removing the "AIS" system is very common.
AIS stands for Air Induction System (or Air Injection System). What it does is force fresh air into the exhaust manifold to burn unburnt fuel that might make its way out of the cylinders after ignition. Why? Emission standards. When the bike gets exhaust pipe upgrades, this system often causes deceleration backfiring--a LOT--and I've witnessed this on some XV250s that replaced exhaust.

It's also ugly (my opinion).

The common removal procedure is to close off the tubes that supply the air, and tuck them away, disconnect all the chrome tubing, and pull the elbow tubing out of the heads. Finally, plug the holes with .45 cal spent brass (because it's a perfectly fitting plug--just freeze the plug and hammer it in--it won't come out). Here is a video of the removal on the 1100. At about 5:00 in, he pops out the tubing that goes right into the cylinder head. https://www.youtube.com/watch?v=H6sF07wRjps

What does the AIS system look like? It's the chrome tubes that wrap around the cylinders and elbow right into an area next to the exhaust ports.

So, our XV250: I covered all of that, because I have seen no reference to AIS on our Virago 250, but we have that system on the XV250. It starts with the left side 'pod' to chrome tubes around the cylinders on the left side, and into the jugs beside the exhaust ports. I'm surprised I've not seen a name for this system mentioned in this forum, but I have seen a few references in this forum to removing the chrome tubes (and I've done a lot of searching and reading about 10 pages deep).

I will be upgrading my exhaust, removing intake pods on both sides, and removing this "AIS". I don't want those short tubes sticking out of the cylinder heads. That would look terrible. I don't care to reverse this, once done right, because I know how well it works on the 1100, so I'm ready to rip em out....

Has anyone actually figured out how to pull the metal tubes that run directly into the cylinder heads and plug the hole in the cylinder heads? I measured the diameter of those tubes, and they look to be about 10-10.5mm which works out to a .40 cal shell casing--maybe! I can just try to knock them out, and be the guinea pig on this, but I'd love to hear that someone else has done it with success, and how they plugged it.

More can be written on the subject, and even added to the "XV250 Left and Right side Pod removal" thread.

Thanks!

- Rob

gruuvinrob
Junior Membership
Junior Membership
 
Posts: 12
Joined: Tue Jul 14, 2015 12:00 pm
  Flag
Bike year & model: 2006 XV250 Virago
Sex: Male

Re: AIS Removal

PostAuthor: gruuvinrob » Wed May 16, 2018 10:31 am

Looks like I might be the first pioneer to pull the elbows and plug the holes. Yikes!

gruuvinrob
Junior Membership
Junior Membership
 
Posts: 12
Joined: Tue Jul 14, 2015 12:00 pm
  Flag
Bike year & model: 2006 XV250 Virago
Sex: Male

Re: AIS Removal

PostAuthor: Hellgate » Wed May 16, 2018 12:37 pm

I'm guessing the short tubes from the cylinder heads are breathers. If so, I wouldn't recommend plugging them. Are they like the ones on you 1100 that come off the cam shaft cover?

Sent from my ONEPLUS A5010 using Tapatalk
Pete
'12 Tuono V4R APRC
'05 R6 Track Bike
'88 RD350 YPVS
'82 XV920RJ
User avatar
Hellgate
Silver Membership
Silver Membership
 
Posts: 1876
Joined: Thu Sep 27, 2012 10:54 am
Location: Austin, Texas Flag
Bike year & model: '82 XV920R
Sex: Male

Re: AIS Removal

PostAuthor: Flyingdog » Wed May 16, 2018 12:44 pm

gruuvinrob wrote:Looks like I might be the first pioneer to pull the elbows and plug the holes. Yikes!


Not really.


Lotta work..instead of just cap'n it off. Beside..you're going to need heat and your working around pretty fragile cylinder fins. They don't just glue back on. But...it's your bike.
You do not have the required permissions to view the files attached to this post.
User avatar
Flyingdog
Silver Membership
Silver Membership
 
Posts: 1860
Joined: Fri Jun 23, 2017 2:31 am
Location: Colorado Flag
Bike year & model: 1985 xv1000 Virago
1981 xv750 Virago
Sex: Male

Re: AIS Removal

PostAuthor: gruuvinrob » Thu May 17, 2018 8:52 pm

Ya might wanna check out the video I posted.

gruuvinrob
Junior Membership
Junior Membership
 
Posts: 12
Joined: Tue Jul 14, 2015 12:00 pm
  Flag
Bike year & model: 2006 XV250 Virago
Sex: Male

Re: AIS Removal

PostAuthor: Hellgate » Thu May 17, 2018 9:12 pm

Sounds like you have it all figured out then.

Sent from my ONEPLUS A5010 using Tapatalk
Pete
'12 Tuono V4R APRC
'05 R6 Track Bike
'88 RD350 YPVS
'82 XV920RJ
User avatar
Hellgate
Silver Membership
Silver Membership
 
Posts: 1876
Joined: Thu Sep 27, 2012 10:54 am
Location: Austin, Texas Flag
Bike year & model: '82 XV920R
Sex: Male

Re: AIS Removal

PostAuthor: Flyingdog » Fri May 18, 2018 1:25 am

:yup:

gruuvinrob wrote:Ya might wanna check out the video I posted.


Good luck with that.
User avatar
Flyingdog
Silver Membership
Silver Membership
 
Posts: 1860
Joined: Fri Jun 23, 2017 2:31 am
Location: Colorado Flag
Bike year & model: 1985 xv1000 Virago
1981 xv750 Virago
Sex: Male

Re: AIS Removal

PostAuthor: gruuvinrob » Fri May 18, 2018 9:10 pm

If you have no idea, then why comment. :banned2: .

gruuvinrob
Junior Membership
Junior Membership
 
Posts: 12
Joined: Tue Jul 14, 2015 12:00 pm
  Flag
Bike year & model: 2006 XV250 Virago
Sex: Male

Re: AIS Removal

PostAuthor: Hellgate » Fri May 18, 2018 9:17 pm

gruuvinrob wrote:If you have no idea, then why comment. :banned2:.
You need to read the rules of the forum. Name calling is not allowed.

Sent from my ONEPLUS A5010 using Tapatalk
Pete
'12 Tuono V4R APRC
'05 R6 Track Bike
'88 RD350 YPVS
'82 XV920RJ
User avatar
Hellgate
Silver Membership
Silver Membership
 
Posts: 1876
Joined: Thu Sep 27, 2012 10:54 am
Location: Austin, Texas Flag
Bike year & model: '82 XV920R
Sex: Male

Re: AIS Removal

PostAuthor: gruuvinrob » Fri May 18, 2018 9:45 pm

Fine with me.... but this post aimed to discover more we can do with the xv250, based on 1. my experience doing similar mods on an 1100, with great success, and 2. hopefully based on some experience of others that might have tried it with an xv250. I included quite a bit of information and a video of it being done on the 1100, so it is certainly within reason that it can possibly be done on the 250 with similar success. And if I do end up being the first to do it, with success, and it ends up being SIMPLE and not scary at all, like you default to thinking it is, then others might be interested in a really good modification! See how this works? No, probably not.

Now, what isn't helpful, and is rather a pain in the @$$, is getting a couple snarky peanut-gallery comments from folks who haven't tried this at all, obviously didn't watch the video, and so just commented about how it probably won't work. It's ignorant commenting.... and, I think you're scared to work on your bike beyond simple tasks.

Maybe that's par for the course on a 250 forum, because a lot of folks who buy 250s are new and just getting into riding. That's fine. If this kind of task isn't for you, MOVE ALONG, because your comments are not helpful, if you've never done it.

Get it now?

I don't expect much more positive to come from this thread. Fine.

gruuvinrob
Junior Membership
Junior Membership
 
Posts: 12
Joined: Tue Jul 14, 2015 12:00 pm
  Flag
Bike year & model: 2006 XV250 Virago
Sex: Male

Re: AIS Removal

PostAuthor: Edward Teach » Sat May 26, 2018 10:32 am

Lucky the Australian bike's don't seem to have ais. After watching the video you could also tap and plug with grub screws...
User avatar
Edward Teach
Junior Membership
Junior Membership
 
Posts: 5
Joined: Thu Mar 22, 2018 12:35 am
Location: South Australia Flag
Bike year & model: 2013 xv 250 virago
Sex: Male

Re: AIS Removal

PostAuthor: Sr.MailMan » Mon May 28, 2018 10:28 am

Edward Teach wrote:Lucky the Australian bike's don't seem to have ais. After watching the video you could also tap and plug with grub screws...


This is what most people have done,to avoid damaging fragile cylinder barrel.
The stub MAY only be pressed in,but what if it isn't?
Good luck with your attempt.
"Forums are like a herd of performing elephants with diarrhea: massive, difficult to redirect, awe-inspiring, entertaining, and a source of mind-boggling amounts of **** when you least expect it."

2011 Yamaha xv250 Around town bobber(84.5mpg),Frisco handlebar,2012 mastercylinder, Jardine full exhaust system,Progressive-440 shocks,Dunlop404(one size over F&R)tires,Oxford heated grips,bar end mirrors,reverse side ignition switch,Shorai 14ah battery,mosfet regulator/rectifier,mini bayonet fuse conversion,LED headlight, signals & dash lights, Lucas(1900era)brake/taillight with 60 LEDs & 2 second/20 flashes bulb,heel/toe shifter & floorboards,carb rejet,Iridium spark plugs & non-resistor plug caps, manual XVS 650 petcock & fuel pump delete,Tachometer/hour meter,XS air filter & A.I. delete,KrankVent,Barnett clutch/springs,17/39 sprockets,O-ring chain,VPsef-94 petrol.

2010 DongFang 250(sold)
2009 Triumph Bonneville T100
1993 Kawasaki Vulcan88(sold)
User avatar
Sr.MailMan
Senior Membership
Senior Membership
 
Posts: 220
Images: 1
Joined: Mon Feb 20, 2012 9:20 am
Location: central CT. USA Flag
Bike year & model: 2011 Yamaha Star xv250
Sex: Male

Re: AIS Removal

PostAuthor: Flyingdog » Tue May 29, 2018 4:59 am

Sr.MailMan wrote:This is what most people have done,to avoid damaging fragile cylinder barrel.
The stub MAY only be pressed in,but what if it isn't?
Good luck with your attempt.


Sr.MailMan...'welcome'..show yer ticket & pull up a chair... plenty of room here in the snarky peanut gallery. :lmao:
User avatar
Flyingdog
Silver Membership
Silver Membership
 
Posts: 1860
Joined: Fri Jun 23, 2017 2:31 am
Location: Colorado Flag
Bike year & model: 1985 xv1000 Virago
1981 xv750 Virago
Sex: Male

Re: AIS Removal

PostAuthor: Jake » Tue May 29, 2018 6:10 am

Hellgate wrote:You need to read the rules of the forum. Name calling is not allowed.



:yup:
This is a family friendly forum. Let's keep it clean and obey the rules.

Guys, I can't read everything, so please use the "Report this post" button when something comes up and I'll handle it.
_______________________________________________________________________
“It ain’t what you don’t know that gets you in trouble.
It’s what you know for sure that just ain’t so.”

~Mark Twain
User avatar
Jake
Mod
Mod
 
Posts: 11858
Images: 108
Joined: Wed Jun 06, 2007 3:18 pm
Location: Penn's Forestland otherwise known as Pennsylvania Flag
Bike year & model: 1996 XV750
Sex: Male

Re: AIS Removal

PostAuthor: gruuvinrob » Tue May 29, 2018 4:40 pm

Sr.MailMan wrote:
Edward Teach wrote:Lucky the Australian bike's don't seem to have ais. After watching the video you could also tap and plug with grub screws...


This is what most people have done,to avoid damaging fragile cylinder barrel.
The stub MAY only be pressed in,but what if it isn't?
Good luck with your attempt.


I removed 90% of the AIS last week. The pods, rubber hoses, and chrome tubes that wrap around the cylinders are all removed. All that's left to remove are the thin metal tubes with the sharp bends that press right into the sides of the cylinder heads right next to the exhaust. I am now even more sure that they just pressed in and will twist and pull right out, just like they did with my XVS1100. For that job, a spent .45ACP casing was the perfect plug. On the XV250, when I removed most of the AIS chrome tubes, the last pieces still attached to the bike were loose enough that I can tell they are just press-fit right in--they wiggled a little when I plugged them.

I'll be replacing the exhaust in a week, I hope, since I have a set coming from Mr. Larish. When I do that, I'll have exhaust out of the way, and I'll be able to better tell how easy this is going to be to pull those last pieces out and press fit in a plug. I am thinking I might get lucky and fit a .40 Cal casing. Wouldn't that be great!? That's how it all went down in the video I posted. I'll take pics, and if it all works out, I'll post a new how-to thread.

gruuvinrob
Junior Membership
Junior Membership
 
Posts: 12
Joined: Tue Jul 14, 2015 12:00 pm
  Flag
Bike year & model: 2006 XV250 Virago
Sex: Male

Re: AIS Removal

PostAuthor: Jake » Tue Jun 26, 2018 7:45 pm

No updates ? Success ? Failure ?
_______________________________________________________________________
“It ain’t what you don’t know that gets you in trouble.
It’s what you know for sure that just ain’t so.”

~Mark Twain
User avatar
Jake
Mod
Mod
 
Posts: 11858
Images: 108
Joined: Wed Jun 06, 2007 3:18 pm
Location: Penn's Forestland otherwise known as Pennsylvania Flag
Bike year & model: 1996 XV750
Sex: Male

Re: AIS Removal

PostAuthor: Flyingdog » Wed Jun 27, 2018 3:43 am

Wonder if anyone has ever hammered a casing and forgot to use one with a spent primer?
User avatar
Flyingdog
Silver Membership
Silver Membership
 
Posts: 1860
Joined: Fri Jun 23, 2017 2:31 am
Location: Colorado Flag
Bike year & model: 1985 xv1000 Virago
1981 xv750 Virago
Sex: Male



Post a reply


  • Advertisement

Return to Yamaha Virago XV250

Who is online

Registered users: Baidu [Spider], Google [Bot], joe231k, scottishbybirth, ttfraz