Remove CA smog equipment & PAIR/KLEEN valve mod '05/'06 ZX6R - ZX6R Forum
 
LinkBack Thread Tools Display Modes
post #1 of 4 Old 03-11-2007, 11:05 AM Thread Starter
Squid
 
xtremewlr's Avatar
 
Join Date: Feb 2007
Location: Coronado, CA
Posts: 80

I Ride: '05 ZX-6R
Remove CA smog equipment & PAIR/KLEEN valve mod '05/'06 ZX6R

I originally posted this how-to on kawiforums.

I decided it was time to remove all the California smog crap off the bike and do the PAIR valve/KLEEN mod. I did NOT use block off plates however, instead I have a hose running to the crankcase vent to provide a vacuum on the crankcase. The idea is that a negative pressure in the crankcase actually helps the piston rings seal better and helps build a little horsepower by removing any positive pressure that builds in the crankcase while the engine is running. Some people also say this will help prevent the popping you get on deceleration after installing an after market exhaust. I haven't found that to be true tho.
I have had this mod on my bike now for over 3000 miles and have not had any issues with it. The bike runs great and is smoother and more powerful than when I fist bought it.

On with the pics!

I won't explain how to remove the gas tank or the air cleaner. If you are thinking about doing this mod, then you had better be able to figure that stuff out on your own (aka - read the service manual).

This first pic is an overall view after removing the air cleaner with everything in place as it came from the factory.



This is how the CA smog stuff looks in place.



First thing to do is remove the smog crap. The 2 lines on the left of this pic go to the bottom of the gas tank, on the right side. The short line coming off the charcoal canister (square box) goes to the PAIR valve and the long vacuum line coming off the separator (little round thing) goes to a vacuum port on the far right side of the throttle bodies.



Smog crap gone.



Next, you remove the PAIR valve.





Plug the vacuum ports on the throttle bodies. I used YELLOW vacuum caps to make them easier to identify. There are 3 ports to cap on the throttle bodies.




I used a brass T connector (you can also use plastic) that is 3/8" at each end. I installed this with 3/8" ID fuel hose and used hose clamps to make sure everything stays in place.



I then routed some more 3/8" ID fuel house from the T fitting and around the left side of the throttle bodies. I cut the stock crank vent hose short and used a 1/2" to 5/8" inline connector (closest that I could find) to go from the fuel hose to the larger crank vent hose. Again, hose clamps at all junctions to make sure the hoses stay put.





Then install vacuum caps on the vacated ports of the air cleaner and only 1 ports on the bottom of the gas tank, specifically the red labeled port. The blue labeled port is a vent that needs to remain open.



This picture of the gas tank shows both ports capped which is actually wrong. Be sure to NOT cap the blue port. The blue port is a vent that allows the gas tank to equalize with atmospheric pressure. If you block it, a vacuum is created inside the tank making it extremely difficult to open the gas cap. I reused one of the vacuum lines from the smog stuff and ran it from the vent to the left side of the bike with the other drain tubes.



Here is the finished product before reinstalling the air cleaner and gas tank.



Here is all the crap that was removed.



Parts wise, you will need to get the following, best bet would be Pep Boys but any auto parts store should have this stuff:

~ 1 T-fitting, brass or plastic, 3/8" at each end
~ Throttle body vacuum caps in yellow x3 - 1/8"
~ Red vacuum caps x2 on air box and gas tank - 1/4" (remember, use only ONE cap on the tank, red port ONLY)
~ Black vacuum caps on air box x2 - 3/8"
~ About 3 feet of 3/8" ID standard fuel hose (do NOT use fuel injection hose)
~ 1 5/8" to 1/2" hose connector, plastic or brass
~ 2 packs of hose hose clamps (4 to a pack usually, we need 7) good for up to 5/8"
~ zip ties
xtremewlr is offline  
Sponsored Links
Advertisement
 
post #2 of 4 Old 03-11-2007, 11:37 AM
Post Master General
 
raized1199's Avatar
 
Join Date: Nov 2006
Location: The Republic of Texas!
Posts: 6,025

I Ride: Then-2001 ZX6R / Now-2010 ER6N
GREAT WORK!
Thanks for the awesome "how - to" with great pics.


Remember...
street lights timed for 35 mph
are also timed for 70 mph.


-->Urban Assault Vehicle<--
raized1199 is offline  
post #3 of 4 Old 03-11-2007, 05:10 PM
World Superbike Racer
 
alor14582's Avatar
 
Join Date: Nov 2006
Location: Fort Lauderdale, Florida
Posts: 1,733

I Ride: 2006 ZX-6r
great work

next track day july 28,29
alor14582 is offline  
Sponsored Links
Advertisement
 
post #4 of 4 Old 03-15-2007, 08:55 AM
SQDBIKE Admin
 
crashtd's Avatar
 
Join Date: Nov 2006
Location: San Francisco
Posts: 2,808

I Ride: 2004 R1 & 2009 Streetfighter
great write up damn those californians and they're anal retentive smog regulations!!

moved to the how-to forum.

-


asphalt & rubber - tlzone - ninja6zone - rsvzone - tuonozone - postwhore - haiku-to-go

Support Ninja6Zone: SUBSCRIBE!!!

Ninja6Zone Forums Staff - Resident Tortfeasor
crashtd is offline  
 

  ZX6R Forum > ZX6R Forum > Guides


Search tags for this page

05-06 zx6r pair mod

,
06 636 throttle plate removale
,

06 zx6r carbon canaster

,

06 zx6r smog removal

,

07 zx6 throttle bodies plugs

,
2007 zx6r evap canister delete
,

636 california gas tank

,
blue and red hoses zx6r
,
how to remove smog equipment on a 2012 zx6r
,

remove smog equipment off of 2004 zx6r

,

zx6r pair mod

,

zx6r pair valve mod

Click on a term to search for related topics.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Parts compatibility list ! Stiggy Mechanical and Technical 153 04-22-2017 12:50 AM
2009 zx6r kleen air mod how to : THUG Mechanical and Technical 59 05-10-2015 05:02 PM
Kawasaki ZX6R Model Designations Lash The ZX6R 25 09-28-2014 09:26 AM
radiator fitment d311monkey The ZX6R 3 06-01-2011 07:19 PM
07/08 ZX6R SMOG PLATES Clean Air Mod ksouc77 Classifieds 0 02-20-2011 03:30 PM

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome