Okay folks, this is a step-by-step walkthrough of how to do the Kleen-air Mod and remove the secondary butterfly plates in your throttle bodies. This instructional is based on an '05 636, is identical on an '06 636, and probably nearly identical on most other ZX6Rs. YMMV.
This will take roughly 1.5 hours.
YOU WILL NEED::
x6 5/16" - 7/8" hose clamps
x1 1/2" Oil Drain Plug bolt
2' of 3/8" Fuel Line Hose
x1 5/32" vacuum cap
x1 7/32" vacuum cap
x1 3/8" vacuum cap
3/8" x 3/8" x 3/8" vacuum T
3, 4, and 5 mm allen wrenches
10mm socket, 10mm wrench
large phillips-head screwdriver
large flat-head screwdriver
To begin, remove the left and right side covers as well as the tank mount bolts. The cover bolts are 4mm, the tank bolts are 5mm.
Next remove the front tank mount bolt, also a 5mm.
Remove the seat mount bolts, one on each side that are 4mm.
Remove your seat. Grab a beer. Eat a snack. Pat yourself on the back because you're doing so well!
Remove the fuel tank pivot bolt. 10mm socket and wrench combo works perfectly.
You can now lift your tank up from the front.
Underneath, you need to release the orange retainer on the left hose. This comes from the fuel pump. Press the legs of the clip together and push them through the black plastic. Once it's started you can pull it to it's "open" position and remove the fuel line. THIS WILL SPRAY FUEL. Put a rag underneath the connector, and hold another in your hand. As you remove the connector, wrap the second rag around the hose.
This is the fuel pump wiring connector. Disconnect it and pass it under the fuel tank mount bar.
Remove the tank and set it aside.
Remove the airbox mount bolt. 10mm socket does the trick.
Pull the airbox injector wiring loom out of this retainer.
Remove all of these connectors. The green pinches from the bottom, the rest pinch from the sides.
Disconnect the upper fuel line from the metal T.
This will also dump a little bit of gas, so have a rag ready. Fuel will also pour out of the metal T. Be warned.
Disconnect the large vacuum line from the back of the airbox. You can pinch this clamp by hand.
On the left side of the airbox, pull this tube off. It goes to the oil catch container.
Underneath the airbox, above every throttle body, is a 3mm allen bolt. Loosen all four of these.
Lift the airbox up from the back to break it free from the throttle bodies. On the right side, disconnect this hose going to the air valve.
This ugly monster is what we'll be removing.
I am NOT kidding around with this part. These screws are very soft metal and have a locking agent on them. YOU MUST USE HEAT. You MUST NOT USE FLAME. Remember that gas you spilled? Yeah, bad idea. Use a heat gun. If you strip a screw, you'll have to stuff the opening with a rag, use a dremel to cut a slot in the top of the screw, and use a large flat-head screwdriver to remove them. I had to do this with 3 of my screws despite my caution and liberal use of heat.
After careful applications of heat, force, foul language, and prayer, you are left with this beautiful sight.
Now for Kleen-air. Pull the air valve out. Remove the small hose at the junction near the throttle bodies. Take the large rubber hoses off and put them on the sides of the vacuum T. Connect the 3/8" fuel line to the 3rd end of the T. Use hose clamps.
Using hose clamps, attach this new T where the air valve was. You can see the nipple of the small junction the other hose went to. We'll block this later. Run the 3/8" hose under the wiring loom, to the right of the throttle bodies, and back to the crankcase vent.
Cap this with a 5/32" vacuum cap.
Optimal routing right there, y'all.
With your knife, carefully cut the crankcase vent hose right at the first bend from the case. I suggest cutting at an angle, to make it easier to insert the 3/8" hose into it. Use a hose clamp and tighten it down.
Finished product should look about like this.