California AIS Removal (99-03)

Written by Mr Tidy

Friday, 11 June 2004

Reprinted by Permission from Mr Tidy's Tech Tips

This is intended for Off Road use only.
Thanks to Paul Yotsuya (Yotsie) for the initial drawings
and instructions for this project

Items below can be removed :

Item #   3:    Charcoal canister to carburetor hose "1"
Item #   4:    Charcoal canister
Item #   5:    Charcoal canister to rollover valve hose
Item #   7:    solenoid valve coupler
Item #   8:    solenoid valve
Item #   9:    solenoid valve to air filter case hose (see note #1)
Item # 10:    solenoid valve to carburetor hose "A"

The above items can be removed and leave the # 2 hose in place,
Some earlier year models had defective rollover valves, Item #6,
which would malfunction and close off, this resulted in quite a few collapsed fuel tanks.
Some have taken the initiative to replace the rollover valve with a small inline fuel filter.
Item #2 is your fuel tank vent hose. This is just an option.

# 1 : When you remove this hose, if you are running a airbox that that has a nipple
          such as the stock air box, place a cap on the nipple.......
          If you are installing an air box or have a air box that has no connection then
          there is no need to do anything.

Pictured is the Air Box side of carburetor.

This hose "A" is Item #10 from up above
that goes to the solenoid valve, this
hose can be removed.

Leave the nipple un-plugged this is the
vent for your float bowl.

Pictured is the back side of the carburetor,

Hose "1" is the vacuum hose to the charcoal canister, Item # 3 from above, you'll want to remove the hose completely.

If viewing from the shifter side between the jugs, it is the hose is on the left-hand side of
the Carb.

Plug off the nipple the hose was removed from
upon the carb~ with a rubber cap which will have to be bought from an auto supply store.

This should conclude the project,
Happy Riding

Questions should be asked in our forum (Use discuss link below). The forum is very active and you stand a good chance of getting your questions answered there. If you would like to leave feedback for the author, or have additional information you think will benefit others, please use the comment section at the bottom of this page.

Discuss this article on the forums. (8 posts)

DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only. Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure. You assume all risks associated with the use of this information. NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION. Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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Comments (6)

Surge tank.
Written by caroadstar, on 09-17-2014 13:36
What is the answer on the surge tank behind the fuel pump. I thought all this was disconnected with the AIS removal?????

Written by 7Dale31, on 09-14-2009 20:39
Had a tec at Yahama remove all my Calif AIS all but the tube that connects the two head so I ordered the AIS kit and finished it off myself runs great and a lot less noise and the tec only charged me 20 bucks and 14bucks for the kit what a deal Dale

Surge tank
Written by RoadieSL, on 05-22-2009 14:11
Does anyone know if I can remove the surge tank behind the fuel pump and the hoses to and from it?

Written by Isriam, on 08-21-2008 12:59
this states "for offroad use only" is that just a disclaimer? i'd like to do this, but not if its going to cause DMV issues.

Written by 07Midnight Star, on 12-12-2006 22:18
On my 07 hose #3 comes from a thing behind my fuel pump. Remove it? Does the ignition rectifier get removed? Ive seen some instructions that shows it gone.
Thanks

Somthings missing here.
Written by 07Midnight Star, on 12-12-2006 22:15

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