removing clean air system - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 8 Old 05-20-2020, 07:37 PM Thread Starter
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removing clean air system

Is it recommended to remove the cas from a 2012 klr650? I saw where someone took it off their bike. what all is involved in removing it? any advice would be helpful. thanks.
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post #2 of 8 Old 05-20-2020, 08:07 PM
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That is the air injection system that adds extra air to the exhaust for emission purposes?
You will not see a performance increase. I believe it is what causes the coughing from the
exhaust when decelerating or descending hills. Its a bit annoying on my bike.
I plan on removing mine as the location of the pump looks like a good place to mount a real horn.
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post #3 of 8 Old 05-20-2020, 09:55 PM
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You will be pulling the vacuum line coming off the carb, so that will need to be capped. No need to cap the line pulled off the frame. AIS is right under the horn.
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post #4 of 8 Old 05-22-2020, 01:26 AM
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Is anyone aware of a tutorial on removing the AIS on the KLR? I checked YouTube and could not find any info.
My Clymer manual has no info on the AIS. I'm sure its not a big job. I tend to overthink things but they get done right.

Terry
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post #5 of 8 Old 05-22-2020, 08:46 AM
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Not that I'm aware of. It is a very simple job. AIS is located on right side of bike, right under the horn. Held in place with 2 fasteners (pretty sure 10mm). Hoses are fairly visible in their routing as well and easy to trace. Hardest part of the job for me was getting the hose to frame connection undone. The only one that needs to be capped is on the carburetor itself, when that hose is removed. That port sticks straight up and is easy to cap. Pretty much a 5 minute job from soup to nuts. Sans the trip to my auto parts store to buy vacuum caps. Sorry I can't provide pics, I'm not near the bike for a week.
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post #6 of 8 Old 05-22-2020, 09:17 AM
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The AIS draws air from the tube from the frame. Is that line connected to the air filter? Does it need to be plugged as well?
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post #7 of 8 Old 05-22-2020, 10:43 AM
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Quote:
Originally Posted by terry_g View Post
The AIS draws air from the tube from the frame. Is that line connected to the air filter? Does it need to be plugged as well?
Believe it or Not, the butt end of the frame has its own air filter for the AIS, to keep the bugs out I guess, retained by a little allen head screw.

So no, about plugging anything other than the carburetor vacuum nipple.

Now if one were removing an Evaporative Emissions systems charcoal can from the LH Rear of a CA approved bike, the rubber elbow ahead of the RH Front corner of the battery needs to be plugged, as it plumbs into the Clean side of air filter box.
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post #8 of 8 Old 05-25-2020, 08:05 PM
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I found the air filter for the AIS. I bet no one has ever changed one.
I went to the local NAPA store and bought an assortment of rubber vacuum caps today.
I removed the AIS pump and capped the spigot at the carb and frame. I removed the steel line
from the head and cut it about 1/2" above the flange and tapped it 8x1.25 and locktited a bolt in the line and
bolted it back on the head. Took it out for a ride and no more backfiring and crackling out the exhaust.
The spot where the pump was mounted looks like a good place to mount a real electric horn.

Last edited by terry_g; 05-25-2020 at 08:56 PM.
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