Once more AIS removal question

Thanks for responding to my posts Hagar.

I pulled the AIS line off the elbow at the rear cylinder and the
inside of the elbow isn't threaded. That's why in my original post I
was concerned about using the 10x25mm bolt.

I have an 04 VStar 1100 custom. I wonder if Yamaha changed the elbow
design. I'll pull the line again just to be sure, but I could swear it
was not threaded.

I'll post back soon.

Thanks again.

Tom

"Hagar" <hagen.DeleteThis@sahm.name> wrote in message news:<kaVIc.20$vA6.8@news01.roc.ny>...
 > The inside of the elbows is threaded, so the 10 X 25mm bolts just screw in.
 > Be sure to use the recommended copper oxide high temp gasket stuff on the
 > bolts, but leaving the first 3-4 threads uncovered.
 >
 > "Tom" <tmonico.DeleteThis@micromeg.com> wrote in message
 > news:59cf4381.0407121622.14b250cf@posting.google.com...
  > > I've read the various postings on the AIS removal. For the elbows in
  > > the cylniders there seems two options. One is to remove the elbows and
  > > hammer plugs into the cylniders. The other is to put a 10x25mm blot in
  > > the elbow with gasket material. The former is so final and the latter
  > > doesn't seem like the best approach. I'm interested if anyone has used
  > > another method to plug the elbows. I'd like to just cap them just like
  > > a vacuum spot, but I'm not sure what to use.
  > >
  > > Suggestions are greatly appreciated.
  > >
  > > Tom<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Once more AIS removal question 

I have heard of, but do not personally endorse, another method in which you
put a vacuum cap in the bottom of the elbow, seal it with the high temp RTV
and then re-install the tubes.
I just removed the whole works and put the plugs in. BTW, they aren't just
hammered in, if you use the aluminum plugs available online at places like
nopork.com you freeze them first. One light tap of a hammer seats them.
These plugs are easy to remove by drilling the center with a 1/4" bit and
inserting a slap hammer screw then the elbows could be re-installed.

Dutch


"Tom" <tmonico.TakeThisOut@micromeg.com> wrote in message
news:59cf4381.0407121622.14b250cf@posting.google.com...
 > I've read the various postings on the AIS removal. For the elbows in
 > the cylniders there seems two options. One is to remove the elbows and
 > hammer plugs into the cylniders. The other is to put a 10x25mm blot in
 > the elbow with gasket material. The former is so final and the latter
 > doesn't seem like the best approach. I'm interested if anyone has used
 > another method to plug the elbows. I'd like to just cap them just like
 > a vacuum spot, but I'm not sure what to use.
 >
 > Suggestions are greatly appreciated.
 >
 > Tom
 ><!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Once more AIS removal question 

When I did mine, also a 04 V-Star Custom, the elbow was threaded. I could
screw the bolt in all the way. Used an Allen wrench on the front, but had to
use channellocks on the rear.

Hagar

"Tom" <tmonico RemoveThis @micromeg.com> wrote in message
news:59cf4381.0407131534.2b531096@posting.google.com...
 > Thanks for responding to my posts Hagar.
 >
 > I pulled the AIS line off the elbow at the rear cylinder and the
 > inside of the elbow isn't threaded. That's why in my original post I
 > was concerned about using the 10x25mm bolt.
 >
 > I have an 04 VStar 1100 custom. I wonder if Yamaha changed the elbow
 > design. I'll pull the line again just to be sure, but I could swear it
 > was not threaded.
 >
 > I'll post back soon.
 >
 > Thanks again.
 >
 > Tom
 >
 > "Hagar" <hagen RemoveThis @sahm.name> wrote in message
news:<kaVIc.20$vA6.8@news01.roc.ny>...
  > > The inside of the elbows is threaded, so the 10 X 25mm bolts just screw
in.
  > > Be sure to use the recommended copper oxide high temp gasket stuff on
the
  > > bolts, but leaving the first 3-4 threads uncovered.
  > >
  > > "Tom" <tmonico RemoveThis @micromeg.com> wrote in message
  > > news:59cf4381.0407121622.14b250cf@posting.google.com...
   > > > I've read the various postings on the AIS removal. For the elbows in
   > > > the cylniders there seems two options. One is to remove the elbows and
   > > > hammer plugs into the cylniders. The other is to put a 10x25mm blot in
   > > > the elbow with gasket material. The former is so final and the latter
   > > > doesn't seem like the best approach. I'm interested if anyone has used
   > > > another method to plug the elbows. I'd like to just cap them just like
   > > > a vacuum spot, but I'm not sure what to use.
   > > >
   > > > Suggestions are greatly appreciated.
   > > >
   > > > Tom<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Once more AIS removal question 

I just pulled the line again and verified that my elbows are not
threaded. They are smooth and a 10mm bolt just barely fits in the
opening. Very strange.

I'd like using the tap in plugs to be my last resort. Why can't I just
cap the elbows with vacuum caps and a hose clamp. I know it wouldn't
be the nicest looking thing, but it's kinda hidden anyway. Seems like
they should work. I'd like to understand the mechanical reason why a
simple vacuum cap won't work.

Thanks for the help.

Tom

"Hagar" <hagen.TakeThisOut@sahm.name> wrote in message news:<9HbJc.109$O%6.100@news01.roc.ny>...
 > When I did mine, also a 04 V-Star Custom, the elbow was threaded. I could
 > screw the bolt in all the way. Used an Allen wrench on the front, but had to
 > use channellocks on the rear.
 >
 > Hagar<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Once more AIS removal question 

I don't know this for a fact, but the elbow is physically between the
exhaust valve and the exhaust port, so whatever you decide to use to cap the
elbow must be resistant to high exhaust gas temperatures, as well as the
pressure. A simple rubber type cap won't fit the bill. Here is a detailed
description of how to do it correctly:
<a style='text-decoration: underline;' href="http://www.star-riders.org/starcruiser/volume4-1/ais_1100.html" target="_blank">http://www.star-riders.org/starcruiser/volume4-1/ais_1100.html</a>

I followed these instructions and it worked fine. Once you apply the
specified compound onto the bolt and let it sit overnight, it will not come
off again (without using force). Check out the site.

Hagen






"Tom" <tmonico RemoveThis @micromeg.com> wrote in message
news:59cf4381.0407141441.55a0a721@posting.google.com...
 > I just pulled the line again and verified that my elbows are not
 > threaded. They are smooth and a 10mm bolt just barely fits in the
 > opening. Very strange.
 >
 > I'd like using the tap in plugs to be my last resort. Why can't I just
 > cap the elbows with vacuum caps and a hose clamp. I know it wouldn't
 > be the nicest looking thing, but it's kinda hidden anyway. Seems like
 > they should work. I'd like to understand the mechanical reason why a
 > simple vacuum cap won't work.
 >
 > Thanks for the help.
 >
 > Tom
 >
 > "Hagar" <hagen RemoveThis @sahm.name> wrote in message
news:<9HbJc.109$O%6.100@news01.roc.ny>...
  > > When I did mine, also a 04 V-Star Custom, the elbow was threaded. I
could
  > > screw the bolt in all the way. Used an Allen wrench on the front, but
had to
  > > use channellocks on the rear.
  > >
  > > Hagar<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Once more AIS removal question 

Thanks. I read that post also, but since my elbows aren't threaded,
this doesn't work for me. I guess I'll have to use the plugs.

Tom

"Hagar" <hagen.TakeThisOut@sahm.name> wrote in message news:<5pwJc.251$O%7.57@news01.roc.ny>...
 > I don't know this for a fact, but the elbow is physically between the
 > exhaust valve and the exhaust port, so whatever you decide to use to cap the
 > elbow must be resistant to high exhaust gas temperatures, as well as the
 > pressure. A simple rubber type cap won't fit the bill. Here is a detailed
 > description of how to do it correctly:
<font color=purple> > <a style='text-decoration: underline;' href="http://www.star-riders.org/starcruiser/volume4-1/ais_1100.html</font" target="_blank">http://www.star-riders.org/starcruiser/volume4-1/ais_1100.html</font</a>>
 >
 > I followed these instructions and it worked fine. Once you apply the
 > specified compound onto the bolt and let it sit overnight, it will not come
 > off again (without using force). Check out the site.
 >
 > Hagen
 >
 >
 >
 >
 >
 >
 > "Tom" <tmonico.TakeThisOut@micromeg.com> wrote in message
 > news:59cf4381.0407141441.55a0a721@posting.google.com...
  > > I just pulled the line again and verified that my elbows are not
  > > threaded. They are smooth and a 10mm bolt just barely fits in the
  > > opening. Very strange.
  > >
  > > I'd like using the tap in plugs to be my last resort. Why can't I just
  > > cap the elbows with vacuum caps and a hose clamp. I know it wouldn't
  > > be the nicest looking thing, but it's kinda hidden anyway. Seems like
  > > they should work. I'd like to understand the mechanical reason why a
  > > simple vacuum cap won't work.
  > >
  > > Thanks for the help.
  > >
  > > Tom
  > >
  > > "Hagar" <hagen.TakeThisOut@sahm.name> wrote in message
 > news:<9HbJc.109$O%6.100@news01.roc.ny>...
   > > > When I did mine, also a 04 V-Star Custom, the elbow was threaded. I
 > could
   > > > screw the bolt in all the way. Used an Allen wrench on the front, but
 > had to
   > > > use channellocks on the rear.
   > > >
   > > > Hagar<!-- ~MESSAGE_AFTER~ -->
 >> Stay informed about: Once more AIS removal question