The kit contains the following parts:
SECONDARY AIR SYSTEM REPLACEMENT
There are various methods of removing & plugging the Pulse-Air system, however this kit is suited to the complete removal of all these parts.
Remove the steel head adaptor.
Ensure the aluminum head is hot enough, so it expands more than the steel adapter, and make its removal easier without damaging the thread. Use a socket with a moderate amount of pressure to remove the steel adapter. In the event the adaptor does not release, soak the adaptor with a mixture of acetone and automatic transmission fluid (50-50) or preferred penetrant.
Install a plug into each head.
Install the 16 mm x 1.5 mm steel plugs, with lots of RED Loctite (not anti-seize) and the 16 x 20 mm crush washers. Retighten the plugs when the head is still hot from riding, torque to 20-25 ftlbs.
Removing all the parts in the air cleaner housing area.
Remove the air cleaner top, and remove the air filter. Remove both metal valve cans, and their plumbing. Do NOT remove the breather hoses and fittings. The breather system is a separate system that serves a purpose - this is connected to a large rubber hose going well forward of the air cleaner housing. In the air filter housing area, at the bottom, center, rear area, there is a tiny dual-flapper-valve that may need replacing (or plugging) to prevent dirty air getting into the engine, see: ManifoldValve162
Remove the pipe fittings on the air cleaner lower housing.
Remove the flexible rubber hoses that connect from the small plastic T adapter to the vacuum valve cans. Plug the hole left in the airbox. All the air going to the carburetor intakes must come from and through the air filter, without outside air entering any open holes.
Remove the very flexible small diameter rubber hoses that went to the carburetors and, plug each carburetor vacuum port with the tiny screw and washer included in the kit.
Plug the holes in the air cleaner housing
Clean the holes at the air cleaner housing on the outside and inside with a good solvent. Apply some RTV to the small diameter end of the plug. Insert the 2 black rubber timing plugs into these holes.
