This video shows how to remove the SAI (secondary air injection) on a 2006, 2007, or 2008 Triumph Daytona 675 motorcycle. The bike in the video is my own personal 2007 Triumph Daytona 675.
This video may be applicable to the Triumph Speed Triple 675 as well or for other model years; however, I did not do the research to verify this information. All suggestions and steps taken in this video are for viewing purposes only. I do not advocate or recommend doing this to your own Triumph, nor will I be held responsible for any potential failures or problems that may arise from following the suggestions in this video.
The steps taken to access and remove the SAI servo are as follows:
1) Remove gas tank (8 mm bolt and sleeve toward rear; two 5 mm Allen bolts at the front)
2) Un-clip gas tank so it may be fully removed (two wiring clips; two overfill hose lines; one main fuel line [a small amount of gas will spill from this hose])
3) Once gas tank is fully removed, un-clip the ECU (two wiring clips) and the air intake sensor (one wiring clip) from the top of the air box, then unscrew the air box cover (eight 7 mm screws)
4) Remove entire air box (loosen six 4 mm Allen bolts on velocity stacks [trumpets]) and single bolt at the front (I can't remember what size; probably 8 mm Allen).
5) After removing entire air box, locate the SAI servo toward the left hand side near the frame. Un-clip this servo, pull it off from its metal tab, then release all three vacuum hoses as depicted in the video.
6) Plug or cap the three nozzles that you released the vacuum hoses from. I recommend first trying to find 1/2 inch rubber vacuum hose caps and pinching them on the nozzles with some stainless steel hose clamps. Another way to do this would be to run a heater or vacuum hose from one nozzle to the other and simply blocking off the nozzle to the air box. PLEASE NOTE: Although I mentioned in the video to potentially use plastic PVC and super glue to block off the nozzles, I DO NOT recommend this method (it may work, but the plastic may melt from the hot exhaust gases; I wouldn't trust the plastic to hold up over a long period of time, but it's your call). Instead, please refer to the note attached in the video for more information on the different ways that will work.
7) Wrap the leftover clip from the SAI that is still attached the bike's main wiring harness. A quick wrap with electrical tape should be fine (simply done to keep the prongs from being exposed to moisture and keep them from corroding).
8) Re-install the air box, ECU and intake sensor clips, and fuel tank. Then change the ECU settings via TuneECU or another tuning software to disable the SAI servo (this will prevent you from receiving a check engine light fault code). Before restarting the bike, I recommend cycling the fuel pump a few times to ensure there is no air in the fuel line (since we unplugged it; if you don't do this, the bike may run rough momentarily).
Voila! Now you are finished. I hope I may be able to help someone out. Thanks for watching, and ride safely!