The AIS pipe leading from the engine has corroded and has a small hole in it.


Given the choice is it better to just replace the pipe (and gasket) with a new one or is it better to get an AGR blank plate and close it off entirely. Does either affect the running?


Please note I do not mind the popping and I do have a Kev mod and DNA filter.


Finally, is it possible to replace this without removing the header pipes first?

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Bike: 2008 XT660Z Tenere with various bits and bobs added or subtracted

The system needs to be sealed either with a new pipe or a elimination plate kit, the only affects will be the reduction in popping when the AIS system is eliminated.

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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

I thought that this was the case.

I guess it just about makes sense to either buy/make a blank and fit it for less then �15.00 instead of buying a new pipe for �32.00 and keeping it standard. Not much in it really.

Is it possible to replace this part without having to remove the exhaust headers?

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Bike: 2008 XT660Z Tenere with various bits and bobs added or subtracted

It'd be a lot less faff if you inserted the correct sized bolt down the tube,obv past any breaks/holes,and secured with a jubilee clip...50p tops!!

Whilst I do agree with you on this, if you read my first post you will see that this is not an option. The pipe has corroded where it meets the flange between the two headers.


Therefore I have a choice:-

1. Buy a new pipe (and possibly a gasket)
2. Buy a blanking kit
3. Make a blank to fit

Having never removed this part (and bike is not available to me for a week or so) I just wanted to know if this can be done without the faff of removing the headers and would I need to replace the gasket.

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Bike: 2008 XT660Z Tenere with various bits and bobs added or subtracted

fair enough ..i did read your post but somehow missed the corrosion bit. is it visible and accessable?..is it a pinprick ?.probably another daft idea would be to 'fill' the corrosion with something like chemical metal or araladite..

However without seeing what your talking about Im just putting ideas out there to try and help..easy now