AIS Removal & Block-Off

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WARNING!: The modifications described in these web pages are for INFORMATIONAL PURPOSES ONLY. I will NOT accept any responsibility if you attempt these modifications yourself. These modification can damage/ destroy/ make the bike UNSAFE/ VOID the Warrantee, injure or cause death to the rider & passenger if the modification are done incorrectly! Seek a Professional motorcycle mechanic if you think your unable to do these modifications yourself or if you think your motorcycle is UNSAFE.  Do the modifications at YOUR OWN RISK!

Now that all the legal mumbo jumbo has been said... I hope these pages help other RS Warrior riders with their mods! Thank you for visiting.

Stay Alert and RIDE SAFE!

Baron AIS Block contents:

This is the Baron AIS kit as it comes from Baron.

Pictures (click to enlarge):

Step 1:

Baron Instructions Step #1 "Remove the air scoop from the left side of the bike."

Remove the two 5mm allen head screws.

Step 2:

Baron Instructions Step #2 "Remove the fuel tank."

Remove the seat and gas tank.

Remove the two 10mm capture nuts from the rear gas tank bracket. Disconnect the two fuel quick-release connectors underneath the seat and the left scoop. Disconnect the two vapor lines from the front left of the gas tank.

Step 3:

Baron Instructions Step #3 "Unbolt fuel connector from the bracket and move aside."

Remove the 8mm bolt from the gas tank fuel quick-release connector. Move fuel quick-release connector aside, after you unbolt it from the bracket..

Step 4:

Baron Instructions Step #4 "Remove the steel air hose from the rear engine stay, disconnect from air box hose."

Remove the 8mm bolt from the fuel supply line bracket going to the fuel regulator. I removed this bracket to make it easier to get to the rear engine stay bolt.

Remove the rear engine stay bolt (14mm).

If your keeping the stock air box, you can remove the steel hose from the rubber hose coming out of the air box extension. Plug the the air box hole with the supplied 1/2" plug and use the stock hose clamp to secure the plug.

Step 5:

Baron Instructions Step #5 "Plug air box hose with supplied 1/2" plug, secure with stock wire clamp."

This is where I deviated from the instructions a little bit. As I no longer have the stock air boxes. I have installed a Do It Yourself BAK kit and coil & sensor relocation Mod on my Warrior. I didn't need the 1/2" plastic plug that Baron provided. I removed the whole unit, where it connects to the AIS pump.

I have indicated where the 1/2" plastic plug should go if you are keeping the stock air box. You can also look in the previous step (picture 4C), where you can disconnect the steel hose and install the plastic plug.

Step 6:

Baron Instructions Step #6 "Find the vacuum line that runs from the rear throttle body to the air pump and disconnect from the throttle body. Cap off the throttle body nipple with the supplied cap, secure with the stock clamp."

Remove the vacuum hose from rear throttle body nipple. Use the supplied cap and install on nipple.

Use a stock hose clamp or a zip tie to secure cap.

To AIS Block-Off Page #2

Text & Photos © Copyright 2008 REDHORSE