Davey D
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| posted on 20/7/09 at 09:27 AM |
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Yaham AIS exhaust port
Im in the middle of doing the AIS removal / breather mod to my 06 5VY engine, and all that is left to do is block the 4x little exhaust ports, and im
wondering what everyone uses?
ive had a look on ebay, and found some aluminium inserts for the older engine, but frankly they cost waaay to much for what is 4 tiny bits of metal
i was looking at tapping / fitting a grub screw in each. Looking at sizes it would probably have to be M8 size? Ive got a set of Taps, and a load of
M8 Grub screws 
im just wondering what the general concensus is of what everyone else does?
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ko_racer
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| posted on 20/7/09 at 09:51 AM |
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You can replace the hollow dowles between the head and rocker cover with solid one. I've got the part number somewhere if you need it.
It's listed in the race kit conversion documentation.
Yamaha Part No:
93608-16M16 (You'll need 4)
[Edited on 20/7/09 by ko_racer]
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a4gom
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| posted on 20/7/09 at 10:40 AM |
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I used some
metal
putty, doesn't look like its ever going to work into anything more than a mess when mixing the 2 parts together but it does eventually and
it sets like bell metal.
Mate used some of the stuff you use for bonding windscreens in.
neither of us have had any problems so far.
Andy
Perfect planning prevents pi$$ poor performance!
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dave107
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| posted on 20/7/09 at 12:10 PM |
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I tapped mine out, not an easy job cannot get tap holder in hits engine, so i held tap in a pair of pliers to support and turned tap with a spanner,
but it did work.
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stuart_g
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| posted on 20/7/09 at 12:11 PM |
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I did exactly what you want to do. I tapped the holes with a 1/4" UNF bolt as they were too big to use M6 tap and then loctited in grub screws.
Have pictures if you want me to post one up.
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Davey D
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| posted on 20/7/09 at 02:47 PM |
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quote:
Originally posted by stuart_g
I did exactly what you want to do. I tapped the holes with a 1/4" UNF bolt as they were too big to use M6 tap and then loctited in grub screws.
Have pictures if you want me to post one up.
That would be great if you could
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Davey D
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| posted on 20/7/09 at 02:48 PM |
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quote:
Originally posted by dave107
I tapped mine out, not an easy job cannot get tap holder in hits engine, so i held tap in a pair of pliers to support and turned tap with a spanner,
but it did work.
i take it you did it in the top ( like im on about) where the ports go in at an angle?
did you tap it out to M8 ?
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Gergely
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| posted on 20/7/09 at 04:16 PM |
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Hi, we have hammered some aluminium inserts (rivet-like aluminium nails or something we found...) into the ports on the rocker cover.
Like this:
 
Modified breather
Gergely
Our build pictures
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Davey D
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| posted on 20/7/09 at 04:55 PM |
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aaah so thats what they are. Ive seen this picture on another thread but i couldnt figure out what youd done to the holes
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bassett
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| posted on 20/7/09 at 09:25 PM |
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Just wondering does removing the ais reduce power as i read somewhere on the older 5PW the ais and exup are there to increase power?
My MNR Blog Updated Jan 2010 - Track Day Prep Begins!
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Davey D
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| posted on 20/7/09 at 09:58 PM |
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quote:
Originally posted by bassett
Just wondering does removing the ais reduce power as i read somewhere on the older 5PW the ais and exup are there to increase power?
Nah.. the exup, and AIS are there just for emissions. It is meant to be easier to map an engine with the AIS blocked, as you dont get the extra oxygen
being pumped into the exhaust giving different readings with a lambda probe
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stuart_g
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| posted on 21/7/09 at 09:17 AM |
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Here is the pic of the grub screws in position.
 
Rescued attachment P1010283.JPG
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Davey D
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| posted on 21/7/09 at 04:05 PM |
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looks good stuart!
i had a look at mine last night, and found that my M7 x 1.0 tap did the job perfectly, so ive got some m7 studs on their way to me that im going to
cut down, and cut a slot in the top so i can screw them in with a screwdriver, as m7 brub screws dont seem to exist
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