... Speedmaster too.

I picked up a new 2007 Triumph Bonneville America yesterday. When I bought it I had done my research and knew I wanted to replace the pipes, pull the AI and install the K&N Air filter system in order to get the most performance and economy as possible out of the fine 865cc Parallel Twin powerplant. So far I have driven it about 250 miles in stock condition over the past twenty-four hours and I now am familiar enough with the machine to know I want more performance and more noise. The dang thing sounds like a sewing machine.

While rolling into Deckers Colorado earlier today, I spied a two-year old (2005) Speedmaster that sounded beautiful. I talked a bit to the rider and discovered that he was running sceptre exhaust and the K&N air filter setup. He had indeed removed the AI and was happy to report that the mods had increased his horsepower by roughly eleven ponies. Giddy-up!

When I picked up the new TBA, I also picked up the AI removal kit. It didn't come with any instructions, but the mechanic at the shop said, "well, you take this 5#!t out and pull out any 5#!t connected to it, plugging the holes as you go."

I felt empowered.

I Googled and Googled, but didn't find any instructions on how to do it. After a little prayer, I decided to give it a shot myself. Turns out the mechanic's instructions were pretty good. When I did it, I had my ten-year-old daughter Sydney (self-portrait included) take pictures and I have written up an illustrated, step-by-step guide for pulling the AI out of your TBA/Speedmaster. I don't warranty these instructions and blah blah blah... Of course, you are on your own. If you break your new bike following my instructions, you're dumb.

Let's get started.

Here is the subject in question. A factory new, stock 2007 Triumph Bonneville America with about 270 miles on it.

Here are the contents of the AI removal kit I bought at the Triumph dealer in Denver.

First, we need to remove the seat(s). If you have the speedmaster seat then you must figure this out on your own. If you have the factory America setup with the pillion, here's how...

• Grab under the back of the pillion, slide the plastic trim out and flip it down. This opens up a hole through which you can insert a 8mm nut driver and easily unscrew the bolt holding the pillion down.
  
  
  
• Next, push the pillion forward about a half-inch and lift up, in order to disengage it from the bolt at the front.
  
  
  
• Next, remove the seat bolt from the rear of the seat. Lift and pull backward to remove.
  
  

Now we will remove the cluster and fuel tank.

• Remove the fuel tank by removing the bolt at the rear...
  
  
  
• Remove the fuel cap and three allen screws from the console...
  
  
  
• Disconnect the electrical connection to the console and set the console aside.
  
  
  
• Turn off the fuel petcock and with pliers, slide the fuel line clamp back and remove the fuel line. (I didn't take pictures of this.)
  
• Carefully lift the back of the fuel tank and slide it backward. reach up under the front of the fuel tank and pull the vent hose from the connection. Remove the tank from the frame and set it somewhere safe.
  
• Here is what the tankless, seatless bike will look like...
  
  

The instructions for removing the air injectors from the top of each cylinder is only photo-documented on the right hand side. Repeat each step on the left side as well.

• Locate the air injection tubes on the top of the cylinder next to the spark plug. Break the silver clamp with a pair of pliers and remove it.
  
  
  
• Slide back the hose clamps on the hose segment on top of the air tube and remove the hose segment and bent metal air tube from the top of the injector tube.
  
     
  
• After repeating the above steps on the left side, remove the injector valve from the frame, just above the engine.
  
  
  
• Remove the large and small hose from the injector valve and follow them back to where they are connected. (large hose to the airbox, and small hose to the carburetor), remove the hoses and plug the holes using the supplied rubber plugs.
  
  Little air hose goes to the fitting between the carb and left cylinder. Remove and plug it
  
     
  
  Big hose goes to the airbox on the left side, behind the chrome, faux air intake. I have removed the chrome cover using a 5mm allen wrench.
  
        
  
• I had three small rubber plugs left over.
  
  
  
  I presume this is due to differences in the AI systems between different year models. if you have more than one small hose, then remove the others and plug them as well. Remember what the Triumph mechanic told me.

Now for the last bit of removal. We need to remove the air injection tubes from the top of the cylinder neads and replace them with the suppplied plugs.

• Using a 13mm box-end wrench, unscrew the air injection tube from each cylinder head. The tube is hard to break loose, but once it does, it comes out with your fingers.
  
     
  
• Using a 14mm socket with a long extension, carefully line up the plug such that the threads don't cross. It should screw in all the way with your fingers. If it doesn't, *STOP* back out the plug and try again!
  
  
  
  Using a torque wrench if you have one, torque the plugs to specs. If you don't have one, tighten the plugs securely but don't bear down. They need to be snug, but not *TIGHT*. Use your best judgement or go get a torque wrench. if you can't find the specs (like I can't) then 15 to 20 lbs should be adequate.

• Re-assemble the bike using the reverse of the disassembly instructions, and you are finished. Don't forget to reconnect the fuel tank vent hose to the fitting up under the console!

When you are finished, you should have removed the following Air Injector parts.



You should have two rubber tubes (fat and skinny), the injector valve body, and the fittings from the injector valve body down to the cylinder heads.

You can either sell it on ebay, box it up for the next owner of the bike, or chuck it. I'm going to keep mine for a while.