AIS Plugging - Star Motorcycle Forums: Star Raider, V-Max, V-Star, Road-Star Forum
 
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post #1 of 10 (permalink) Old 05-22-2015, 03:00 PM Thread Starter
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AIS Plugging

Hey guys,

I know I've made a post about this before. I plugged the elbows with .45 shells, cut a slit in the side to let it open up to fit over the elbow. I've successfully plugged the front head AIS elbow, just slid right over it and I put a metal clamp on it. The rear one I cut shorter as there is little room in there to work. Fit it on, was tighter than the front one. Ended up using a wrench as a pivot point to hammer it in. Well...that proved to not work so well... I don't know why the rear one would be a slightly larger OD than the front but it is. The shell is spread out from where I notched it but I can't get it to go all the way in obviously. Now there is a tiny hole I can't cover and I need some suggestions. Help please! As I am missing prime riding time here in Ontario and the damn thing is still in my living room.




1999 Yamaha V-Star 650 Custom
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post #2 of 10 (permalink) Old 05-22-2015, 03:04 PM Thread Starter
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Is the direction of flow away from the head and not into it? If so I'll just clamp it as is and throw some RTV on it.

1999 Yamaha V-Star 650 Custom
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post #3 of 10 (permalink) Old 05-22-2015, 04:15 PM
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you stuck the shells on the ends of the elbos, your supposed to take the elbos out.If the elbos were out you could put a bolt with some high temp. rtv sealant in.
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post #4 of 10 (permalink) Old 05-22-2015, 04:19 PM Thread Starter
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I'm not that mechanically inclined and i've broken too many bolts on the block so far and didn't trust myself enough to take them out as I heard they are press fitted and a bitch to get out.

And I meant to say JB Weld, not RTV. Just going to throw it on an old bolt and shove it up there.

1999 Yamaha V-Star 650 Custom
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post #5 of 10 (permalink) Old 05-22-2015, 04:27 PM
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sounds like a plan
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post #6 of 10 (permalink) Old 05-22-2015, 05:23 PM
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There are some decent YouTube videos on this, including removal of the elbows. Might pay to seek those out and have a go at getting them out...
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post #7 of 10 (permalink) Old 05-22-2015, 08:30 PM
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i use .357 magnum or .38 special shells with black rtv. they slide into the elbows, and when the rtv cures, dont come out. no clamps needed
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post #8 of 10 (permalink) Old 05-22-2015, 11:41 PM
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Remove the elbows and tap your shell casings into the hole. It's really not that hard.

'08 VStar 1100 Classic
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post #9 of 10 (permalink) Old 05-24-2015, 09:30 AM
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Seems as though when i did mine it was a few phones ago so no pictures avilable from me right now. Honestly not to hard to get the elbows out the rear was easy just pliers some on blaster and some wiggling it came out. The front I just used a long screw driver and a hammer a few light taps and it came out. There not in there tight at all.

2008 V-Star Silverado 1100. K&N filter, airbox mod passenger floor boards, all light visors, ISO grips, Cobra slash cut mufflers, Saddleman touring seat/ tourpack. Lots of little extras.
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post #10 of 10 (permalink) Old 05-24-2015, 10:05 PM
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JB Weld worked for me. I dont have access to spent casings so I do what I have to do. AIS is gone looks and runs better, and only spent $5. for the JB weld. Looks great when I'm passing you on the highway.
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