XT660Z – Removing AIS

By XT-660.de & Roy Reisefuehrer

Remove the hose that runs from the AIS valve to the air filter box.
Open the clamp with a pair of pliers and slide it down from the connection,
then pull off the hose.

The connection to the air filter box must now be closed, otherwise the motor
would suck in unfiltered air. There are several possibilities for this.
I closed the hole with a “car tire valve”
As a precaution, I also locked the other side. To do this, I took the small tube
from AIS and blocked it with a “car tire valve” too.
Here is the AIS
Just pull out the plug.

and then make this "open" plug waterproof and dustproof with a "thumb" from
a rubber glove.
The AIS valve is only fitted with rubber dampers. Now loosen one of the
clamps on the connection hose with careful force, pull the AIS valve upwards
and pull the hose off at the same time.
The AIS valve is out and the air filter box is blocked. Now only the exhaust
side is missing.

It makes sense to remove the left exhaust manifold and the protection so that
you have the opportunity to get to the exit of the AIS with your fingers. Pull off
the exhaust manifold towards the front. Pay attention to the lambda cable !!!
Hang the exhaust manifold securely with cable ties, otherwise the cable could
tear. In order to be able to mount the locking plate, the connection must first
be removed.
This is quite a fiddly job because the frame is in front of it.
It is advisable to shorten a 5 mm allen key with the angle grinder to approx
1 cm so that you have a chance to losen the bolt.
When the flange is down, clean all sealing surfaces and put some heat-
resistant sealing on it.
There is a precisely fitting AIS plate from OTR.
Or you can do something yourself.
Tighten the AIS plate with the original screws.
The loud slap after closing the throttle is immediately gone.
Short version to stop the banging
If you don't want to remove the whole AIS, this is enogh, to stop the banging