Extremity
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So I just completed my AIS removal - not just blocking off the pipe, but actually ripping out the entire system and using block off plates. I know there are a lot of posts on the subject but I have not seen any pictures and I actually had a REALLY hard time figuring out what to do due to the lack of information. Most of this will be really obvious to you guys, but some people (like me) don't know how to properly remove the battery box, air box, etc, the first time. After completing it, I figure it will only take somebody who knows where everything is about 20 minutes; it took me 2 hours 
Before we start-
Here's a link to Roth Industry's AIS "smog plates" for the Fz6. It comes with everything you need, including a plastic piece to block off the port on the airbox you will no longer have a hose connected to.
Roth Industries — Smog Plates
A pic of what I received only three days after ordering!
Second - MAKE SURE YOU READ THIS TO SAVE YOURSELF A TREMENDOUS AMOUNT OF TROUBLE
There is an electrical connection that both of the hoses from the plates your new smog plates are replacing end up at. It is very obvious, it's the "heart" of the entire thing, if you pull the hoses out you will know what I'm talking about. You can't leave this unplugged! I made this mistake and spent 45 minutes trying to figure out why my bike wouldn't start, and then I had to take everything apart again (and putting the airbox back on multiple times is a pita). You can buy caps at any hardware store or do what I did - wrap electric tape around the unused openings on the piece and just leave the electric plug connected, and stuff it somewhere out of the way. The piece has no more hoses connected to it, it's just it's own piece, so as long as it's not going to get in the way of anything you don't need to worry about having a super-secure seal on it.
I only have two pictures because I didn't event think about taking them until it was two late, but they should still help anybody new to this. Your first step is to take off the side fairings (if you have them) with an allen wrench, and then lift your tank. This isn't something you're going to be able to do while holding the tank up so bungie it so it stays vertical. I would suggest unplugging at least the top (white) electric connector from the bottom of your tank, it will be pulled very tightly.
This is a great time to check if your air filter needs to be replaced/cleaned by taking out the phillips screws on top of the airbox and setting it aside. It also makes putting the airbox back on after you are finished WAAAAY easier. There are two bolts connecting the airbox to the battery box, remember to undo those before trying to take it off. Aside from those two bolts it is only held in place by rubber clamps, you can try to loosen them with your allen wrench but it's a pain in the ass. Don't be afraid to put a little muscle into taking it off, you wont damage anything unless your rubber is EXTREMELY old and brittle, I've got an 05 that sits outside every day and had no problems, rip that sucker off.
While you are working with the airbox, unplug the hose coming out of the front-right (towards headlights, front brake side) of the airbox and cap it with the rubber piece you received with the plates, well applied tape, or whatever your personal preference is.
After the airbox is out (remember to remove the two bolts on the battery box) you can remove the battery box itself. I took the ground off, wrapped it in some electric tape, and just left the positive connected (mine is a pain to get off) and pulled the battery box as far down/to the side as I could. There is a bunch of stuff behind it/connected to the back of it, I don't know what any of it is called but there are two pieces with two connections on alternating sides (assuming whatever sends power to spark plugs). Don't be afraid to disconnect things, you will need to in order to get enough clearance (you will need a lot of room back there), just mark them along the way so you know where to plug them back in. Once you are able to pull out the entire battery box, set it aside.
(Note: This is a GREAT time to do the 2 lowbeam headlight mod! I had my cable ordered from BD43 that sat around for months, and I installed it in 30 seconds since I was already in here. Plan multiple mods and do them all at once!)
There is a rubber piece covering the top of the engine that acts as a heat shield. Underneath this are the hoses/parts you need to access. There is one port that you need to block on the left and right sides of the bike, and then the "heart" with the electrical plug at the top, near the connectors you would access to do the headlight mod. Don't be afraid to lift most of it out to get down there, it's pretty easy to put back and is very flexible.
Here is a picture of the area/part you will be accessing:
I didn't have a clean cloth so I covered up the openings to the engine with two trash bags to prevent getting anything in there - you really, really want to keep those internals as clean and dirt-free as possible. Be careful!
The red arrow points to my NEW smog plate that I had already installed. In place of that you will see an older plate with a hose protruding from it. Don't worry about taking the hose off, just use your allen wrench and take off the two bolts holding it down (you'll need to put some muscle into it to break them free, but I was able to do it by hand using the frame as leverage) and save them as you will need them for the new plates. Take it off, pull the hose out, install your new plate and make sure you secure it tightly. Repeat for the other side.
The blue arrow points to the area where you will find the electrical connector that needs to remain plugged in, and where all of the hoses meet. The gold lines show the general path/position of each hose.
Closeup of installed plate:
Once both plates are installed and the hosing is taken out, make *sure* that plug is still hooked up securely. Put everything back together carefully, as most of it needs to be in place before you can check to see if the bike will start. Take your time putting the rubber heat shield back into place, chances are it will have shifted to one side. Mine was protruding from the right side of the frame when I put it back and I had to take a few minutes shifting it back into place - not only does having it in the wrong position look bad, but you leave potentially crucial parts/connections vulnerable to very high heat. Don't rush it! Also take your time positioning all of the stuff you moved, it's a fairly right fit back there and if you just shove it in you might have a hard time getting the battery box back in.
If you can fit the battery box back in with ease and get those bolts down, you're pretty much done. I'd suggest firing up the bike ASAP - leave the tank unbolted, just pop the plug back in and rest it down. Make sure it runs and that you didn't forget anything before you get all of the cosmetic pieces put back on.
You're done! Unlike others I still experience significant popping from my exhaust but I think it's from running rich due to my Two Bros pipes and hollowing out my cat. I have noticed slightly better throttle response, however. Sorry that I didn't remember to take more pictures, I tried to make up for it by rambling with random details. I'm good at being descriptive, if anybody needs help finding something or has any other questions feel free to ask or PM me! Happy modding! :rockon:
Before we start-
Here's a link to Roth Industry's AIS "smog plates" for the Fz6. It comes with everything you need, including a plastic piece to block off the port on the airbox you will no longer have a hose connected to.
Roth Industries — Smog Plates
A pic of what I received only three days after ordering!
Second - MAKE SURE YOU READ THIS TO SAVE YOURSELF A TREMENDOUS AMOUNT OF TROUBLE
There is an electrical connection that both of the hoses from the plates your new smog plates are replacing end up at. It is very obvious, it's the "heart" of the entire thing, if you pull the hoses out you will know what I'm talking about. You can't leave this unplugged! I made this mistake and spent 45 minutes trying to figure out why my bike wouldn't start, and then I had to take everything apart again (and putting the airbox back on multiple times is a pita). You can buy caps at any hardware store or do what I did - wrap electric tape around the unused openings on the piece and just leave the electric plug connected, and stuff it somewhere out of the way. The piece has no more hoses connected to it, it's just it's own piece, so as long as it's not going to get in the way of anything you don't need to worry about having a super-secure seal on it.
I only have two pictures because I didn't event think about taking them until it was two late, but they should still help anybody new to this. Your first step is to take off the side fairings (if you have them) with an allen wrench, and then lift your tank. This isn't something you're going to be able to do while holding the tank up so bungie it so it stays vertical. I would suggest unplugging at least the top (white) electric connector from the bottom of your tank, it will be pulled very tightly.
This is a great time to check if your air filter needs to be replaced/cleaned by taking out the phillips screws on top of the airbox and setting it aside. It also makes putting the airbox back on after you are finished WAAAAY easier. There are two bolts connecting the airbox to the battery box, remember to undo those before trying to take it off. Aside from those two bolts it is only held in place by rubber clamps, you can try to loosen them with your allen wrench but it's a pain in the ass. Don't be afraid to put a little muscle into taking it off, you wont damage anything unless your rubber is EXTREMELY old and brittle, I've got an 05 that sits outside every day and had no problems, rip that sucker off.
While you are working with the airbox, unplug the hose coming out of the front-right (towards headlights, front brake side) of the airbox and cap it with the rubber piece you received with the plates, well applied tape, or whatever your personal preference is.
After the airbox is out (remember to remove the two bolts on the battery box) you can remove the battery box itself. I took the ground off, wrapped it in some electric tape, and just left the positive connected (mine is a pain to get off) and pulled the battery box as far down/to the side as I could. There is a bunch of stuff behind it/connected to the back of it, I don't know what any of it is called but there are two pieces with two connections on alternating sides (assuming whatever sends power to spark plugs). Don't be afraid to disconnect things, you will need to in order to get enough clearance (you will need a lot of room back there), just mark them along the way so you know where to plug them back in. Once you are able to pull out the entire battery box, set it aside.
(Note: This is a GREAT time to do the 2 lowbeam headlight mod! I had my cable ordered from BD43 that sat around for months, and I installed it in 30 seconds since I was already in here. Plan multiple mods and do them all at once!)
There is a rubber piece covering the top of the engine that acts as a heat shield. Underneath this are the hoses/parts you need to access. There is one port that you need to block on the left and right sides of the bike, and then the "heart" with the electrical plug at the top, near the connectors you would access to do the headlight mod. Don't be afraid to lift most of it out to get down there, it's pretty easy to put back and is very flexible.
Here is a picture of the area/part you will be accessing:
I didn't have a clean cloth so I covered up the openings to the engine with two trash bags to prevent getting anything in there - you really, really want to keep those internals as clean and dirt-free as possible. Be careful!
The red arrow points to my NEW smog plate that I had already installed. In place of that you will see an older plate with a hose protruding from it. Don't worry about taking the hose off, just use your allen wrench and take off the two bolts holding it down (you'll need to put some muscle into it to break them free, but I was able to do it by hand using the frame as leverage) and save them as you will need them for the new plates. Take it off, pull the hose out, install your new plate and make sure you secure it tightly. Repeat for the other side.
The blue arrow points to the area where you will find the electrical connector that needs to remain plugged in, and where all of the hoses meet. The gold lines show the general path/position of each hose.
Closeup of installed plate:
Once both plates are installed and the hosing is taken out, make *sure* that plug is still hooked up securely. Put everything back together carefully, as most of it needs to be in place before you can check to see if the bike will start. Take your time putting the rubber heat shield back into place, chances are it will have shifted to one side. Mine was protruding from the right side of the frame when I put it back and I had to take a few minutes shifting it back into place - not only does having it in the wrong position look bad, but you leave potentially crucial parts/connections vulnerable to very high heat. Don't rush it! Also take your time positioning all of the stuff you moved, it's a fairly right fit back there and if you just shove it in you might have a hard time getting the battery box back in.
If you can fit the battery box back in with ease and get those bolts down, you're pretty much done. I'd suggest firing up the bike ASAP - leave the tank unbolted, just pop the plug back in and rest it down. Make sure it runs and that you didn't forget anything before you get all of the cosmetic pieces put back on.
You're done! Unlike others I still experience significant popping from my exhaust but I think it's from running rich due to my Two Bros pipes and hollowing out my cat. I have noticed slightly better throttle response, however. Sorry that I didn't remember to take more pictures, I tried to make up for it by rambling with random details. I'm good at being descriptive, if anybody needs help finding something or has any other questions feel free to ask or PM me! Happy modding! :rockon:
