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Installing a british customs Air Injection Removal Kit
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Step 1:Secure bike and remove the seat with a 5mm Allen wrench.This will allow access to the gas tank and will let you disconnect the battery before starting installation.
Using a 8mm wrench, remove the two gas tank screws and move tank back.With the gas tank loose, remove fuel line from fuel valve by compressing the spring clamp. Remove gas tank vent line (black hose from tank) and remove tank from bike.
Step 3:Remove the air injection controls from the bike. Remove the two black hoses from the air injection tubes located on each side of the head. Trace the two black hoses that were removed from the air injection tubes on the head to the factory air box. Remove both hoses from air box and valve assembly. The air injection valve assembly can be removed with a 13mm wrench in two pieces. Remove air injection tubes from cylinder head.
This is a picture of the air injection pump. You can leave it disconnected or remove it complletely.For carbureted models:The carburetors and intake manifolds should be easy to access at this point. Remove all the hoses from the carburetor and manifold and follow them back to the charcoal canister.
Step 5:FOR CARBURETED MODELS: With the factory hoses removed from the carburetos and manifolds, use the supplied four rubber vacuum caps to plug the factory fittings. There is one fitting on each carburetor/manifold that needs to be plugged.
Pro TipThis step can be performed with the carburators still mounted to the motorcycle.
Remove left side air box cover using a flat blade screwdriver. With cover removed, plug air injection with supplied plug on the factory air box. Once plugged, reinstall side cover.
Step 7:Install supplied air injection block off screws on both sides of the head with copper sealing rings on each side. Tighten screws to 20 Nm using a 5 mm Allen wrench.
Refer to step 2 to re-install tank. Install vapor line to tank and route to desired location to vent.
Torque specs:Seat screws 5mm Allen wrench at 10 Nm
Installation Complete!Congratulations! You have successfully completed the installation of your new British Customs Air Injection Removal Kit.