remove these frame plugs and loosen the screws deep inside there. they are small allen i believe. this allows you to pull off the airbox.

you should be looking at this now

remove these bolts. theres 2 per plate.

remove the plates and the hoses that are attached and the pair valve all as 1 piece.

install these block off plates. i used ivans.

this is the white plug you need to jumper. hard to see but i used a small staple.

then tape it up.

use this included vac plug to plug the bottom of the airbox

final step.
put it all back together making sure to reattach any necessary cables and hoses that you didnt eliminate, making sure to secure hoses and electrical somewhere safe.

i apologize for some of the blurry pics. i think my phone got mad at me for treating it like a camera lol.

 

first impressions after starting for the first time..

bike seems to actually run a little smoother.
it seems to have more power right off idle.
i couldnt be happier with the results.

 

thanks to this post it took me about 10 minutes to install my k&n filter today!
i did what you did by spinning the gas tank around and laid it to rest on a towel placed on my seat.

i'm in the process of ordering the block off plates, but not sure if this will help with the factory exhaust system?
my first impressions are the same as yours with just the filter installed. bike runs a lot smoother!

 

Awesome write up...
few questions though and excuse me if i missed it..

is there some sort of kit that you got the block off plates and vac plug from? and if so where can we get it?
i'm assuming that this mod keeps from recirculating the ventilated air from the valve cover?

 

http://www.ivansperformanceproducts.com/

 

Excellent write up! The 07/08 certianly appears to be more of a pain in the ass to work on that the 05/06 are.

 

hey tecate, sorry to bring this up but what exactly is the benefit of doing this , in detail? Smoother powerband? more power?

and what was the total damage in terms of replacment parts you had to order for this mod..?? Thanks!!

 

First reason for doing this mod is if you have a aftermarket exhaust and dont like popping on deceleration. Second reason if your like me and taking your bike to a dyno to have it tuned without removing the smog stuff you can't get an accurate air/fuel mixture. Several people make block off plates. Tecate and myself got Ivans block off plates for $35 bucks plus shipping.

 

why do you need to put a juper on that plug? would you still need to if you use the Kit ECU

 

why do you need to put a juper on that plug? would you still need to if you use the Kit ECU

i know the kit ecu is ok with the exhaust servo removal but im not sure about the jumper from the kleen valve.

 

is this the jumper mod every ones talking about??? i all so would like to know if this will help with stock pipes

 

me too

 

no it isn't the jumper mod...that is a connector under your seat and you need to search it and do it...free 11+ whp....

this is only necessary with an aftermarket exhaust....so you can tune...or if you just wnat to drop a good amount of weight off the cali spec bike

 

no it isn't the jumper mod...that is a connector under your seat and you need to search it and do it...free 11+ whp....

this is only necessary with an aftermarket exhaust....so you can tune...or if you just wnat to drop a good amount of weight off the cali spec bike

Am I correct in saying that its only US bikes that have less power than our UK/European models?

So this modification is of no benefit to a UK ZX6?

 

where did you get some hex wrenches long enough for the ones holding down the airbox, I got the longest ones I could find at lowes and they still come up short

 

is there anyone in california that sells these

 

on there site they dont show the plates for the 07 zx6r

 

stupid question... what does kleen stand for?is it only on second gen 636's?

 

never totally block off the vent for the crack. There is a filter that is needed...still need to vent... or BOOOOOOMBOOOOOOOM

 

Can someone clarify? Anyone have a pic? I don't want to blow my $#!% up. I'm thinking you meant "crankcase" in place of "crack" yeah?

 

this is the white plug you need to jumper. hard to see but i used a small staple.

then tape it up.

so all you did here was stick a staple in the connector and tape it up. And to make sure this does keep the FI light off when removing that valve thing? I know this is an older post but the way i have it now is that valve still plugged in and just zip tied out of the way

 

once you remove the valve, if you dont jumper that plug, the ecu will see its removed and you will get the red light blinking. yes just a staple just like the jumper mod.

 

But if you change the stock exhaust hence bypassing the exhaust valve... just leave the valve module plugged in under the seat and you wont need to jump the plug and no 'FI' or flashing red light will appear! The ECU will be none the wiser b'cos jumping the plug wont effect the ECU's operation anyway as it still thinks the valve is there! I left mine plugged in but just pulled out the two cables which run to the factory exhaust so if / when I go to sell the bike and they want all stock crap then its all still there! easy!

 

subscribed

 

awesome, I'm def doin' it...oh and thanks for the PICS!!!

 

not exactly the kleen air mod. yes it eliminated the smog pumps but you never relocated your crankcase tube from the back of your air box. to complete the setup get a k+n filter and vent your crank case and cap the back of the air box.

 

not exactly the kleen air mod. yes it eliminated the smog pumps but you never relocated your crankcase tube from the back of your air box. to complete the setup get a k+n filter and vent your crank case and cap the back of the air box.

where does the crank case vent from? does it go to the airbox separately from the Kleen plates?

also looking at the wire diagram....(confused)... so when does this actually vent?

 

run a long hose from your crank case vent to this T valve.= if you are going to stunt or frequenty wheelie the bike. and cap the back of the air box where it normally goes in.

if you are going to race and not wheelie the bike, use the block off plates on your valve cover and put a K+N crankcase filter on , and cap the back of the airbox.

 

racing says u need to put it into a catch can though. a filter could blow oil every where

 

you need to replace the pump motor with a T valve from autozone or pepboys... something 1/2 inch or equal to the diameter hose you are running from your crankcase.

 

thanks

 

I love it! My bike runs so much smoother now. I recomend getting this to everyone. Thanks for the writeup!

 

So has anyone done a complete Kleen air mod on an 07 yet?