Kleen air mod help - ZX6R Forum
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post #1 of 14 Old 07-06-2015, 03:48 PM Thread Starter
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Kleen air mod help

There are so many different threads of how to do the Klein air mod and most of the how to's are different from each other.
I need everyone's opinion on the way I was told to do it. (This how to was from a buddy of mine that parking lot stunts his 636
I am doing this on a 2005 636

Instead of block off plates he used a T to connect the 2 ports and a hose coming from the T with a small air filter on the end and then ran a hose from the crankcase with another small air filter on the end and mounted both filters as high up and towards the front of the bike as possible. Then plugged up the necessary holes with vacuum caps.

What's your opinion on thiss
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post #2 of 14 Old 07-06-2015, 04:09 PM Thread Starter
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Currently I have the Kleen air mod where they connect the crankcase to the 2 ports on top of the motor with a T. All that's doing is causing me to burn a shit load of oil in the exhaust.
Note: I tend to do super long wheelies. Usually atleast 5 minutes floating around in the balance point
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post #3 of 14 Old 07-06-2015, 06:46 PM
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get with Kawboy and them in chicago they can help you out
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post #4 of 14 Old 07-07-2015, 05:25 AM
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I dont stunt so I cant speak for that community, but that being said, there is really only one proper way to modify the SAI system:

1. Remove all the hardware from the valve cover and install blockoff plates. For 06 and earlier models, all you need to do is plug the vacuum nipple previously used to control the solenoid. For 07+ models, you should jump the plug for the electrical connection.

2. Plug the nipple on the bottom of the airbox that previously connected to the SAI system.

3. DO NOT modify the PCV system as it is there for a reason and the vacuum produced by the airbox helps to aid in the venting of gasses.
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post #5 of 14 Old 07-22-2015, 07:00 PM
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Thanks for the help
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post #6 of 14 Old 08-30-2015, 02:44 PM
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Quote:
Originally Posted by Ebster1085 View Post
I dont stunt so I cant speak for that community, but that being said, there is really only one proper way to modify the SAI system:

1. Remove all the hardware from the valve cover and install blockoff plates. For 06 and earlier models, all you need to do is plug the vacuum nipple previously used to control the solenoid. For 07+ models, you should jump the plug for the electrical connection.

2. Plug the nipple on the bottom of the airbox that previously connected to the SAI system.

3. DO NOT modify the PCV system as it is there for a reason and the vacuum produced by the airbox helps to aid in the venting of gasses.
i'm no expert on the subject just trying to figure it out. so the pcv is the hose coming off the lower side of the block and the sai is to vent from the topside of the block (valve cover)? and from my understanding of the mod, the sole purpose of the mod for stunters is to stop oil from spilling into the airbox in extreme angles or a lay down.

an another question, so does the sai route unburned gasses back into the fuel system on throttle off/deceleration? i notice on the lower side of the rpm range on decel it sounds an feels like theres a popping/backfire switch that jus turns on when the rpm hits the lower half of the range? or i mean like theres a couple second delay once im off the throttle an then the popping/backfire switch is turned on an sounds like the engine is gurggling on decel.
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post #7 of 14 Old 08-30-2015, 04:15 PM
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On the factory race bikes the hoses that come from the valve cover are plugged. The switch solenoid and other BS is removed. The hole in the air box is capped and that's it. No need for block off plates. There is actually a part number for the plugs, clamps and cap. That's how I ran the ZX10.

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post #8 of 14 Old 08-30-2015, 11:32 PM
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Quote:
Originally Posted by TheEvilTwin View Post
On the factory race bikes the hoses that come from the valve cover are plugged. The switch solenoid and other BS is removed. The hole in the air box is capped and that's it. No need for block off plates. There is actually a part number for the plugs, clamps and cap. That's how I ran the ZX10.
but the crank case breather is still hooked up to the airbox?
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post #9 of 14 Old 08-31-2015, 08:15 AM
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Quote:
Originally Posted by fashionrider View Post
but the crank case breather is still hooked up to the airbox?
YES.
It has to be. Under no circumstances do you plug that one or you risk overpressurizing the crankcase.
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post #10 of 14 Old 08-31-2015, 06:56 PM
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Quote:
Originally Posted by TheEvilTwin View Post
YES.
It has to be. Under no circumstances do you plug that one or you risk overpressurizing the crankcase.
thats the reason why in extreme angles or in a crash people hydrolock correct? because most if not all stunters disable the bank angle sensor or the bike will want to shut off doing some tricks or when ever the cage touches the ground.

an the crankcase vent tube is hooked up to the airbox to prevent over pressurizing an to suck out fumes an throw it back into the fuel system? or is that the other one? the one on top the valve cover?
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post #11 of 14 Old 09-01-2015, 05:52 AM
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Quote:
Originally Posted by fashionrider View Post
so the pcv is the hose coming off the lower side of the block and the sai is to vent from the topside of the block (valve cover)?
Yes

Quote:
Originally Posted by fashionrider View Post
and from my understanding of the mod, the sole purpose of the mod for stunters is to stop oil from spilling into the airbox in extreme angles or a lay down.
Not, not really. From my perspective (a track day rider, not a stunter) the sole purpose of the mod is to remove the SAI system from the bike which results in better A/F readings for tuning and also reduces popping on decel as there will be less combustion in the exhaust system. As ET stated above, I have never altered the PCV line and it should ALWAYS remain intact.

Quote:
Originally Posted by fashionrider View Post
an another question, so does the sai route unburned gasses back into the fuel system on throttle off/deceleration? i notice on the lower side of the rpm range on decel it sounds an feels like theres a popping/backfire switch that jus turns on when the rpm hits the lower half of the range? or i mean like theres a couple second delay once im off the throttle an then the popping/backfire switch is turned on an sounds like the engine is gurggling on decel.
Almost correct. It routes cold intake air into the exhaust system to help ignite unburned gasses and fuel that make there way out of the combustion chamber and into the exhaust.

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post #12 of 14 Old 09-01-2015, 09:02 AM
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Quote:
Originally Posted by fashionrider View Post
thats the reason why in extreme angles or in a crash people hydrolock correct? because most if not all stunters disable the bank angle sensor or the bike will want to shut off doing some tricks or when ever the cage touches the ground.

an the crankcase vent tube is hooked up to the airbox to prevent over pressurizing an to suck out fumes an throw it back into the fuel system? or is that the other one? the one on top the valve cover?
Regardless of mods, the engine is designed to be operated while upright. Give or take 30* but not laying on its side or 12 oclocked. There are two ways hydrolock can happen. Either fluid on top of the piston or underneath. If oil comes up the crank vent and into the air box then it "could" end up on top of the piston through the intake. If the bike is running on its side then oil could wash under the low cylinder and prevent it from coming down when the con rod pulls it.
To help prevent the first condition, you could pull the vent tube off and put one of those little filters on it or route it to a catch can.
The second problem is the nature of the beast. I've seen a couple bikes lock up after crashing on the track and not shutting down.
TBH,, I'm not 100% familiar with the hose routing on the 636. So I can't say what that is for specifically. But yeah the vent tube allows the fumes to get sucked into the air stream and burned in the engine.

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post #13 of 14 Old 09-01-2015, 11:26 AM
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Quote:
Originally Posted by TheEvilTwin View Post
Regardless of mods, the engine is designed to be operated while upright. Give or take 30* but not laying on its side or 12 oclocked. There are two ways hydrolock can happen. Either fluid on top of the piston or underneath. If oil comes up the crank vent and into the air box then it "could" end up on top of the piston through the intake. If the bike is running on its side then oil could wash under the low cylinder and prevent it from coming down when the con rod pulls it.
To help prevent the first condition, you could pull the vent tube off and put one of those little filters on it or route it to a catch can.
The second problem is the nature of the beast. I've seen a couple bikes lock up after crashing on the track and not shutting down.
TBH,, I'm not 100% familiar with the hose routing on the 636. So I can't say what that is for specifically. But yeah the vent tube allows the fumes to get sucked into the air stream and burned in the engine.
Damn I didn't know it can hydrolock from the bottom side to. I've only heard of hydrolocking from the topside. I'm sure the topsides are way more common the the bottom sides tho right?
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post #14 of 14 Old 09-01-2015, 02:03 PM
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Quote:
Originally Posted by TheEvilTwin View Post
Regardless of mods, the engine is designed to be operated while upright. Give or take 30* but not laying on its side or 12 oclocked. There are two ways hydrolock can happen. Either fluid on top of the piston or underneath. If oil comes up the crank vent and into the air box then it "could" end up on top of the piston through the intake. If the bike is running on its side then oil could wash under the low cylinder and prevent it from coming down when the con rod pulls it.
To help prevent the first condition, you could pull the vent tube off and put one of those little filters on it or route it to a catch can.
The second problem is the nature of the beast. I've seen a couple bikes lock up after crashing on the track and not shutting down.
TBH,, I'm not 100% familiar with the hose routing on the 636. So I can't say what that is for specifically. But yeah the vent tube allows the fumes to get sucked into the air stream and burned in the engine.
Damn I didn't know it can hydrolock from the bottom side to. I've only heard of hydrolocking from the topside. I'm sure the topsides are way more common the the bottom sides tho right?
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