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HOW TO: Smog Block Off's (removal of air pump/smog block off install

71K views 237 replies 82 participants last post by  ekchaveng 
#1 · (Edited)
OK, so I installed my AGG Racing smog block off's today and while I was at it...I snapped a few pics so that I could write up a detailed HOW TO on this common mod.

UPDATE:12.10.12
buy beer before proceeding with mod. BlueMoon preferably.


UPDATE 1.0 : 12.10.12
make sure you reuse the original gasket from the reeds.
1. Remove the little screws and pop out the the reeds... Like so:


2. Once you remove all the screws and reeds.... This is what you're left with:


Simply drop in it and install the block offs right over them.



UPDATED:10.21.12
BLOCK OFFs can be picked up from AGG Racing (justin) great guy.

if you have the following tools...the install will be much easier and faster...I highly recommend these.
-1/4 rachet
-1/4 socket
-#5 allen for the 1/4 socket


So here we go.

You will need to remove your fuel tank, air filter, and entire airbox to gain access to the air pump. If you are not familiar on the process to remove the fuel tank and airbox assembly....let me know and ill do a seperate write up on that. This write up will begin right when you are about to remove the air pump.

1. Once you remove the air box assembly...this is what you will see. IMPORTANT NOTE: Notice the yellow marking in the center...there will be a plastic rivet located there...use a Phillips flat head and pop it out...then slide the metal plate to the right to remove the plastic cover. Once you remove those two things...the cover is held in place by pressure tabs...just pop them out


2. Once you remove the platic cover...you will see the following (the hoses will be connected to the air pump in the middle...i took the pic after removing them, lol)
Remove the hose clamps from the left and right sides of the air pump, then detach the hoses from the air pump like pictured. NOTE: Unplug the electrical harness from the air pump as well. Once you remove these three things from the air pump, you should be able to remove the air pump completely from the bike, set it aside


3. Once the air pump is out of the way...remove the two hoses that are left...my clamps were facing the radiator and I was unable to reach them...so I gave them a good tug and out they went. Notice the pale green electrical harness...you will zip tie that harness to the main harnes behind it before you tidy everything up...not now though...so leave it alone.


4. Once you remove both hoses...you can pull the black heat cover back and this is what you should see. NOTE: Notice the female plug to the left of my pinky? right below the left nipple? There is a harness that is plugged into this receiver...if you unplug this harness, it makes it ALOT easier to reach the Alen bolts on the left nipple. If you remove this harness...MAKE SURE YOU PLUG IT BACK IN BEFORE CLOSING EVERYTHING UP!


5.Remove the bolts holding down the nipples (two per nipple). I did not take a pic of the reeds after removing the nipples...but when you remove the nipples, needle nose pliers make this easier, you will expose the reeds...when you remove the reeds...this is what youre left with...

When you remove the reeds...makie sure you take everything out...here is the complete reed assembly once removed.
Top of reed:

Bottom of reed:


6. Once you remove the reeds...get your AGG Racing smog block off's, if you dont have AGG block off's...youre a douche for buying anything else. Before you install the block off's...make sure you use blue locktite on the bolts.


7. Drop the plates in and tighten the bolts down...you can snug them down and then a quarter turn and you should be fine...you have locktitie on them so dont crank them down.



8. After installing the blocks off's and tightening the bolts....zip tie the air pump plug to the main harness...like so...just so that it doesnt bang up against the radiator or hits the fans.


9. Last but not least...when you removed the air box assembly...you had to unplug an air hose that went from the air pump to the bottom of the air box...use the black plug that is provided with the block off's and plug the opening on the bottom of the air box.....like so.


10. After pluging the hole on the bottom of the airbox...start putting everything back together...youre all set to start tunning your bike correctly or to simply get rid of the "pop" when decelerating from high RPM's.

ENJOY!!!

Please feel free to correct any of my steps if I screwed up.
 
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#49 ·
Re: Smog Block Off's (removal of air pump/smog block off install

i installed my block off plates facing the other way is this an issue?

If you are looking at the bike from the front tire you can read the AGG racing on mine, I see you did it the other way, you can read the writing from sitting on the seat

if you dont know hopefully AGG can chime in
 
#50 ·
i installed my block off plates facing the other way is this an issue?

If you are looking at the bike from the front tire you can read the AGG racing on mine, I see you did it the other way, you can read the writing from sitting on the seat

if you dont know hopefully AGG can chime in
I don't think it matters bro. The logo is just a logo on these, there is no front or back to them.

Correct me if I'm wrong justin.

Sent from my SAMSUNG-SGH-I997 using Motorcycle.com App
 
#51 ·
They work the same either way. :fact
 
#52 ·
Re: Smog Block Off's (removal of air pump/smog block off install

they work the same, but the logo definitely should go facing up. and not just b/c it's awesome... b/c there is a slightly larger chamfer on the top edges vs. the bottom. the bottom has more area and therefore is more suited to be the base.
 
#54 ·
Re: Smog Block Off's (removal of air pump/smog block off install

yea i dont have it upside down i can read the writing lol, i just have the writing facing the other way... appreciate it one less thing I have to do for my build
 
#60 ·
Re: Smog Block Off's (removal of air pump/smog block off install

Thanks for your instructions. They worked flawlessly. I couldn't, no matter how hard I tried, to get the hoses off the nipples. So I just cut them. Also someone with larger hands may benefit from rounded allen keys. There isn't much room at all. It probably took longer than it should have, only because on each screw I could only turn 1/4 of a rotation each time.
 
#61 ·
Thanks for your instructions. They worked flawlessly. I couldn't, no matter how hard I tried, to get the hoses off the nipples. So I just cut them. Also someone with larger hands may benefit from rounded allen keys. There isn't much room at all. It probably took longer than it should have, only because on each screw I could only turn 1/4 of a rotation each time.
Lol, no problem bro. I have somewhat small hands and it took me a while as well. There's no much room but do-able. Glad I was able to help you out bro. :cheers

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#62 ·
Re: Smog Block Off's (removal of air pump/smog block off install

I'm going to be using your woodcraft instructions later today. I'm going to post a question in there now..
 
#71 ·
Can I get the full how to with gas tank removal and airbox
Will do bro. I may have some time this evening. If you're in a hurry, search for the service manual PDF and it goes over the proper procedure. Either way, I'll post up a HOW TO this evening.


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#72 ·
Re: Smog Block Off's (removal of air pump/smog block off install

:popcorn:
 
#75 ·
Re: Smog Block Off's (removal of air pump/smog block off install

great write up.
 
#79 ·
Re: Smog Block Off's (removal of air pump/smog block off install

nicely done!
 
#83 ·
hoping to get my PCIII and block offs installed this weekend. thanks for the write up.
:Cheers

Let us know how it goes and if you have any questions... Feel free to post here or PM me. If you need help ASAP... Pm and ill shot you my number.


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#85 ·
Well I got my PCIII in, but no luck with the block off plates. Originally was going to order them from AGG, but when i went to put them in the cart it said he was out, so I went to STG and ordered some Graves ones only to find out a week later that STG didn't have any either. So I'm still waiting on plates, STG was suppose to have them shipped directly to me from Graves.


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