GEN II DETAILED SMOG PUMP REMOVAL AND BLOCK OFF

[chrisjp]

I went ahead and on my GEN 2 prepared it for a ECU flash i am getting done. it already has a FULL SYSTEM Yosh R-77 4-2-1 system with a PCV and AUTO TUNE (but dont think it had the dual band o2) and quickshifter all by DYNOJET.. i was not happy with the auto tune, still had some after fire issues and wanted to at least disable in the ECU flash for the smog pump. so i took pics while doing this and hope it helps you do this fairly simple modification. so... here we go!! lol

 

[chrisjp]

first thing is get the bike stable (i use front and rear stands.) now you dont need to disconnect the battery or what not but now remove the driver seat by the two bolts on the side under the seat

 

[chrisjp]

now with the driver seat off.

 

[chrisjp]

now located the two bolts that hold the take down and take allen head wrench.

 

[chrisjp]

go ahead and remove those two bolts.. now i use 550 cord to hold the tank up as apposed to the lift rod supplied with the bike (which mine did not have when i bought it used and all the modifications i listed already on it) tie off the cord to the rear seat lock assembly then tie off the tank all the way up (i use a slip knot so it cinches as i lift it and i pull it snug so it stays up completely out of the way

 

[chrisjp]

now lets disconnect what is needed to pull the air box up and off the bike. you do NOT have to disassemble the air box, you can leave it intact but i did because it helps me line it back up over the throttle bodies when i put it back together.. so locate these connections and rubber hoses coming up from the engine and remove them

 

[chrisjp]

now remove the front bracket that holds the throttle cables out of the way (10mm bolt head)

 

[chrisjp]

now you need to loosen the clamps that are on the throttle bodies... allen head on both sides of the bike.. loosen them just enough to pull off the throttle bodies. (i did 6-7 full turns and still had enough to continue to unscrew without it coming apart

..

 

[chrisjp]

now you can firmly pull the airbox off the throttle bodies... there will be one more hose to disconnect from the smog pump but easier to reach once air box assembly up and off the throttle bodies

 

[chrisjp]

now you have the air box off and out of the way... and you will see the smog pump and connections on top of the head

 

[chrisjp]

disconnect the smog pump electrical connection and if you get your ECU flashed you can just tuck it out of the way as it is then disconnected in the ECU flash...if you ARE NOT getting your ECU flashed.. you will need a jumper connection so that you do not get a error FI code.. they can be bought from our great org sponsors.. just give them a message!!.

 

[chrisjp]

now with the electrical connection disconnected go ahead and take the bolts off above each reed assembly on top of the head.. again here are pics showing what two alllen head bolts you will be unscrewing

 

[chrisjp]

now you can simply push the smog pump off the silver bracket that holds it on and remove it

 

[chrisjp]

now throw that dirty dirty thing where it belongs!!

 

[chrisjp]

now underneath you will see the seal and reed assemblies, use a screwdriver as shown to pop them off but dont throw them away you will need them in the next step.

 

[chrisjp]

the reason you need them (depending on the block off plates you have (or if you choose to put gasket material on the openings if you going for total weight loss...but i find its easier to go to the gym...lol... now remove the screws that hold the reeds onto each of the plates.

 

[chrisjp]

now you can put the plates with their original gaskets back onto the head (both are symmetrical and it matters not which one you put where)

 

[chrisjp]

take the allen head bolts that held the assembly from the smog pump and your plates you purchased from one of our great org sponsors... use just a dab of BLUE locktite and then center the plates on top of the reed assemblies and then tighten them down.

 

[chrisjp]

ok now you got that done.. there is one last thing.. you need to block off the air box assembly smog pump inlet. there is a wide variety of ways to do this.. if you didn't get from a org sponsor.. i believe a 5/8 leg cover from lowes work.. (rumor) .. i took off the smog pump connection one of the clamps and used it to assist to secure the rubber boot i had.. the clamp was a little loose as the boot was thinner than the hose...so i simply compressed it the opposite way to make the ring smaller...then put it over the boot as additional measure to make sure it stays on

 

[Bumblebee]

Good detailed write up....this should have been a sticky for future viewing..