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AIS exhaust cap ideas

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ImageUploadedByThumper Talk1401671751.197528.jpg

My GYTR AIS removal kit exhaust cap blew off today. I followed all the instructions for initial installation and retightening, but it never was a really secure fit. Does anyone have a suggestion for another method of capping this port off, or do I need to buy another GYTR kit?

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does that get pressurized when its capped or did it just fall off from vibration or w/e??

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Mine doesn't feel secure either but has stayed on.

 

There's a thread somewhere about removing the fitting, tapping the port and inserting a plug. 

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I think you can find rubber caps at Pep boys Etc. or epoxy it.

 

A rubber cap won't work for that fitting as it's straight out of the exhaust port and is too hot.  

 

"Epoxy it" >> High temp sealer might work. Been tempted to do that myself but GYRT design looks like it's intended for expansion/contraction of that fitting. Not sure if a sealer is right in this application??? Don't know??

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The GYTR AIS kit is junk...

 

Not sure what year your bike is but this could help you:

 

http://www.thumpertalk.com/topic/996006-economical-2005-6-wr450-ais-removal/

 

No need to tap anything anything as in thread tapping just remove the fitting on the head and 

tap in the plugs referenced in that posting...

 

Damn, wish I saw that before GYTR robbed me. VERY NICE sir.

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I definitely like the concept of the freeze plugs, but without being certain that a 2012 wr250f could use the same size plug as a 2005 wr450f, I didn't want to remove the existing pipe. I did find another solution though...

ImageUploadedByThumper Talk1402014002.416600.jpg

It's a stainless steel compression cap. It tightens down very securely, much tighter than the GYTR cap. That being said I haven't ridden it yet, but so far it's looking very promising.

I put a couple sharpie marks on it to recognize any loosening due to vibration, and I'm considering safety wiring it.

I wish I would have seen this before dropping the $60 on the GYTR kit. After rejetting with the JD jet kit, the only remaining GYTR pieces from the AIS removal kit are the two rubber caps. I'm sure I could have found those anywhere for almost free.

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I have had a rubber cap and a zip tie on mine for 3 years now and its perfectly fine.

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Here in NZ you can buy a kit that does away with the AIS for $1:50. Comes with all the brackets / plugs / carb jets etc

You not get the kit in the US?

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I will try to get a picture up of mine, the second one I havd had, both with gtyr kits but a stst bracket that bolts onto the barrel where the earth strap fir the starter motor bolts to and prevents the plug from coming out,

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I have had a rubber cap and a zip tie on mine for 3 years now and its perfectly fine.

 

There are 3 "openings" that need to be covered after removing the AIS. Are you sure you put a rubber cap on the fitting coming out of the exhaust port?

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I definitely like the concept of the freeze plugs, but without being certain that a 2012 wr250f could use the same size plug as a 2005 wr450f, I didn't want to remove the existing pipe.

 

 

From what I can see in the parts fiche it should be the same size pipe coming out of the head so the plugs should fit...

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Use those 12.1mm plugs last night on my 2006, but holy **** that exhaust pipe is **** to remove so this is what i did:

Drill 8.5mm

Tap M10 x 1.5

Connected my work's trusty slide hammer like such

4-5 Tugs with all my strength and alas, it came out.

 

Caps were a breeze to install by comparison. Also put two in there just in case. Its quite the press fit. i could have never gotten it out with locks or pliers.

 

Enjoy,

IMG_4838.jpg

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There are 3 "openings" that need to be covered after removing the AIS. Are you sure you put a rubber cap on the fitting coming out of the exhaust port?

 

 

Yes I am quite sure. You will have to zoom in a bit but its visible in this pic. Like I said, 3 years without a problem, it doesn't even look or feel deteriorated. I was paranoid when I first put it on because I figured it would melt as well, but its just as good as the day I zip tied it on!

 

IMG_1093.jpg

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Haa! go figure.

 

your bike looks mighty shiny senor. You sure you ride it? ; |

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Haa! go figure.

 

your bike looks mighty shiny senor. You sure you ride it? ; |

 

The real question Devo83 is what kind of cleaner/degreaser do you use?? That's a clean ride 

 

Hahaha, I'm smiling like a proud dad!  Yah I ride her all the time! I just happen to have got it off the original owner, who babied it, and I may be slightly OCD when it comes to keeping it clean and maintained. Anyways, hope the rubber cap idea (and proof!) saves a few headaches. PS - Spray 9 for degreaser, and lots of elbow grease!

 

IMG_1097.jpg

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