Fitting instructions for the Thunderbike Air Injection Removal Kit to fit the carb model Triumph America, Bonneville, Scrambler, Speedmaster, T100 and Thruxton

1. AIR INJECTION REMOVAL
KIT FOR CARB MODEL
TRIUMPH AMERICA,
BONNEVILLE, SCRAMBLER,
SPEEDMASTER, T100 &
THRUXTON
Thunderbike Engineering Ltd
2/46A Muritai Street, Tahunanui, Nelson 7011, New Zealand
Tel: +64 (0)3 548 5787
parts@thunderbike.co.nz www.thunderbike.co.nz
www.facebook.com/ThunderbikeEngineering

2. AIR INJECTION REMOVAL KIT FITTING INSTRUCTIONS
(CARB MODELS)
1. Remove seat bolts and remove the seat.
2. Remove the negative wire from the battery's negative terminal.
3. Turn fuel tap off, remove fuel line from tap.
4. Lift rear of tank to access fuel tank breather pipe located on the opposite side and
forward of fuel tap. Remove pipe and fuel tank.
5. Slide back the band clamps and remove the rubber hoses connecting the
air injectors to the air injection valve, slide back the band clamps then remove the
breather tube connecting the air box to the air valve. Install the hole plug
(supplied) into the air breather box.
6. Remove the rubber hose connecting the air valve to the carburetors.
Replace with rubber cap (supplied) on the carburetor.
7. Remove air valve from frame by removing the 2 bolts.
8. Remove the air injectors with a 13mmdeep well socket or wrench. Note:
it’s a tight fit with minimal clearance so you may need to modify a tool to suit
If the injector is difficult to remove BE PATIENT. Try soaking the
base of the injector with penetrating oil.
9. Install the stainless steel AI Bolts using the supplied
copper washers. Torque to 15- 20 ft/lbs or "snug" if no torque wrench is
available. DO NOT OVERTIGHTEN. Note: Place a couple drops of
anti-seize on the threads as this will aid in the removal later if necessary.
10. Install remaining removed parts in reverse order.
STOP NOW YOU HAVE FINISHED!!
Thunderbike Engineering Ltd
2/46A Muritai Street, Tahunanui, Nelson 7011, New Zealand
Tel: +64 (0)3 548 5787
parts@thunderbike.co.nz www.thunderbike.co.nz
www.facebook.com/ThunderbikeEngineering