Modification Procedure

1. Open the hood and install fender covers on both fenders.





2. Disconnect the intake air temperature sensor connector, vacuum hoses, and remove the air cleaner assembly.





3. Disassemble the secondary air filter case from the air cleaner assembly and remove the secondary air filter from the case.

CAUTION:
Wear protective eye shields when performing the two following operations.





4. Using the 18 mm stepped drill (Unibit), drill out the secondary air nipple hole to 18 mm. Do not allow the hole to extend to the outer diameter of the nipple. Remove any burrs around the hole with a knife when finished.

Note:
The stepped drill's biggest diameter is 18 mm.





5. Clean the secondary air filter case by using compressed air. Reassemble the secondary air filter into the case and remount the case to the air cleaner assembly.

CAUTION:
Make certain that NO loose chips are left in the secondary air filter case.





6. Cover the carburetor air horn with a clean shop towel.





7. On the carburetor, locate the secondary high altitude air bleed tube and vacuum hose. Disconnect the vacuum hose from the bleed tube.

8. Insert the 1.4 mm drill into the pin vise.





9. Liberally coat the drill bit with grease, making sure to pack the drill's flutes thoroughly.

Note:
Coating and packing the drill with grease will help to prevent drill "chips" from getting into orifice and tube.





10. Using the 1.4 mm drill and pin vise, slowly drill out the 0.9 mm secondary high altitude air bleed tube orifice.

11. Wipe away any grease left on the bleed tube. Using appropriate safety equipment (eye shields, low pressure blow gun, etc.) blow away all debris remaining from the drilling procedure.

12. Remove the shop towel from the carburetor.

13. Reconnect the intake air temperature sensor and vacuum hoses and reinstall the air cleaner assembly.





14. Under the flap of the Emission Recall Completed Label write in your 5-digit dealer code, Carefully remove the white paper from the backside of the flap. Press the now clear flap portion onto the label.





15. Carefully remove all dirt and oil from the areas on the hood as shown. Affix the Emission Recall Completed Label.