AIS Removal & Block Off Page 2

AIS Removal & Block-Off

Page 2 of 2

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!

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Step 7:

Baron Instructions Step #7 "Remove the air pump assembly from bracket; disconnect air lines from head fittings."

Remove the four 8mm bolts. You can then slide the AIS pump away from the bracket, to get to the air lines going to the AIS elbows.

Disconnect both air lines from the AIS elbow fittings.

Step 8:

Baron Instructions Step #8 "Disconnect fuel line and move bracket aside."

Remove the two 8mm bolts and the 6mm allen head bolt to remove the bracket.

To remove fuel connector remove plastic cap (already removed in top picture). Depress both gray buttons (top & bottom) on the connector and slide off the fuel connector.

Disconnect the fuel supply line to the Fuel regulator. After this is completed you can set the bracket and fuel regulator aside, to get better access to the elbow fittings on each cylinder.

Step 9:

Baron Instructions Step #9 "Remove the elbow fitting from each cylinder head and replace with supplied block off plates using stock washers and screws."

Remove the 5mm allen head bolts from the AIS elbow fittings.

Using the stock washers and bolts, block off each cylinder with the supplied block-off brackets.

*** From this point on, you should apply some Blue Loctite to all the bolts as you reinstall them onto the Warrior.

Step 10:

Baron Instructions Step #10 "Reinstall fuel line bracket and connect fuel line."

Reinstall the two 8mm bolts and the 6mm allen head bolt for the bracket.

Reconnect the fuel line. Make sure you feel or hear the connector click for a positive connection. Re-attach the plastic cap over the fuel connector.

Reconnect the fuel supply line.

Step 11 & 12:

Baron Instructions Step #11 "Reinstall engine stay bolt on rear cylinder."

Reinstall the 14mm engine stay bolt on the rear cylinder.

Baron Instructions Step #12 "Reinstall fuel line to the bracket."

Reinstall the gas tank quick-release connector onto the bracket with the 8mm bolt.

Step 13:

Baron Instructions Step #13 "Reinstall air scoop and tank."

Reinstall gas tank. Make sure gas tank quick-release connectors 'clicks' when you make the re-connections. You also have to reconnect the two vapor lines in the front-left of the gas tank. Reinstall the two 10mm Acorn nuts on the rear gas tank bracket. Reinstall the seat.

Reinstall the left scoop using the two 5mm allen head bolts.

Project AIS Block-Off: COMPLETED

Here is a picture of all my 'Take-Off' parts. If you still have the stock air box, you'll still have the plastic air box extension with the 1/2 plug still attached to the main air box. The steel air hose/bracket would still be discarded.

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