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Discussion Starter · #1 ·
Ok, so I finally got around to taking off the airbox and trying the Secondary Air Injection removal.

Exhibit A; the offending party.


I took off the tank, removed the two mounting screws which hold the airbox on and pulled off the airbox after unplugging the SAI connector and other airbox hoses.

Once I got the Airbox off, I took the SAI solenoid off and created a block-off plate out of aluminum as seen in this photo;



I then removed the 3 SAI hoses attached to the motor and found 3 plugs, generally used to cap off vacuum systems. I inserted each plug (closed end into the open valve) and then threaded in a stainless bolt to each as seen in this photo;



Next I moved to the 'California Model' carbon canister bolted under the injectors.



I just removed the two bolts, took off the entire bracket and unplugged all the connections. One problem I might need to fix later is that the tip-over hose on the fuel tank goes into that canister and branches off into a motor breather. If anything needs to be plugged in differently I'll post up later.

Anyway, I took another couple plugs and capped off the disconnected 3-way connection where it branched off to the CC and left the electrical connection on the CC valve solenoid connected. I just zip-tied it to a hose to keep it from swinging around. I might just wire up another resistor to that connection later too, but it works fine for now.



So, with all that finished, I put the airbox and tank back on and started up the bike. Voila! No check engine light, and strangely, the bike seemed to have a hair deeper growl and a smoother sound. Perhaps this is because the O2 sensor is now getting a TRUE reading without all that SAI BS? I let the engine warm up and gave it a rev all the way up to 9,000 RPM and NO BACKFIRING! Holy ***** thats a first for this bike! Normally, I'd rev it up to even just 6,000 RPM and it'd let off a moderate POP. Now its nothing, just clean revving and sounds great. I've got a lot more planned for this bike in the future, but thats all for now.

 

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Discussion Starter · #4 ·
!!!UPDATE!!!

I uploaded the Non-SAI PK tune I found on t595.net. However! The resistor I installed overheated and melted through both the shrink tubing AND electrical tape making a strange smell and getting me worried for a few minutes. I unplugged both solenoids though and still no check engine light, so its all good.

Just install a non-SAI Tuneboy tune and you can unplug both the carbon canister solenoid AND the SAI solenoid connections with no adverse effects.

Also, the bike seems to sound a bit deeper/bassier now.
 
G

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I was wondering about that resistor but my bike is a 49 state version so I've got no experience with SAI. Plus, it sounded like you were on top of it. :)
 

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Discussion Starter · #6 ·
Bob got a CAD design for the SAI block-off plates and should make a few sets in the coming weeks. Let me know if anyone is interested in buying a set. We're probably going to sell them for $100 a set, all billet, and will offer different finishes for added cost. Shipping included in $100 price tag for USA 48 states.
 

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An alternative to the plates is just put a ball bearing in the hose and leave the stock plates in place. All this for just the price of one ball bearing at Ace Hardware. You can't see anything with the tank and airfilter in place anyway.
Mad`
 

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Discussion Starter · #8 ·
I've got rubber caps with bolts screwed in to ensure they don't come out. I can take photos to show how visible my caps are. You might not be able to see the middle one, but you can most definitely see the ones on either side.
 
G

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I agree. I have had deactivated/blocked the SAI on my 05S3, but ordered a set of Kukulka's plates in order to clean things up a bit.
 
G

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Kuhkla, I PMed you for an address to send a check. but first i am a little concerned about
the question of putting in a resistor ( getting it over heated) or just disconnecting the line
( and getting an engine light on ) . The dyno guy told me he does the Power commander
with the SAI disconnected. i'll discuss that with him tomorrow
 
G

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Kuhlka,
I used a self etching primer and engine paint to dress up the block off plates I bought from you. A touch of Loctite on the screws and everything went onto place easily. Even though the SAI on my 2005 Triple is different, without the servo and related tubing, the engine looks just like yours in the photos above - much cleaner.

Now to install some cold air tubing to feed the airbox... ;)
 

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Discussion Starter · #16 ·
Oh awesome! So there it is! Verification that the plates fit the 1050. Thats good to know.

Nice to hear you like the product.


Tracker, the resistor I used melted. I'm going to be redoing this post in the near future to clarify somethings. Basically, you can block off the SAI and leave everything plugged in. I'm interested in hearing how your dyno tech does his SAI disconnect. If you guys could send me some pics of how you did your 1050 block-offs, I can host and post them up.
 
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I was figuring that you could leave everyting plugged in ( but thanks for the verification).
The PC install/tune is a continuing nightmare ( a VERY long story). If I EVER get the bike back I'll be surprised if it is not damaged!!!!
 
G

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Tracker,
Before I removed all of the SAI stuff on my 2005 Triple, I simply put a small piece of tape over the SAI inlet hole inside the airbox. It worked well, but completely removing all of the SAI parts has allowed me to build a "cold air intake" panel (it blocks heat from radiator, engine, and header) where the SAI parts used to be - in front of the airbox.
 
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Tracker,
What details would you like? Removing the SAI is fairly straight-forward.
-Remove the hose from the front of the airbox.
-Remove the screws from SAI panels on the top of valve cover - two screws each (6 total).
-Unplug SAI solenoid.
The SAI now can be removed in one piece.

Using Kuhlka's block-off plates:
- Use 6 screws from above, place each plate covering SAI inlets on valve cover and tighten securely - not tight, the gasket is soft rubber 9nm/80 in-lb torque. [The plates only go on in one direction - they are thicker at one end than the other to give coils clearance.]

Make sure SAI hole in front of the airbox is covered with tape.
Use non-SAI tune from dealership or Tuneboy.
NO MORE POPPING - well, only once in a while, but very mildly.

I hope this helps.

Photo of block off plates and new "cold air intake" shielding:
 
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