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07/08 zx6r kleen air mod

105K views 100 replies 45 participants last post by  wingnutks  
#1 · (Edited)
this is gonna be a long post so bare with me.
first off lets get the legal disclaimer out of the way.

this mod is intentioned for off road racing use only. use of this mod may void your factory warranty. this mod may cause your motorcycle to violate emissions laws. i take no responsibility for any mechanical difficulties or injuries caused from attempting this modification. this particular modification applies to the 07/08 kawasaki zx6r only.

ill do my best to post corresponding pics for each step. to some of you more advanced at working on these bikes might seem like alot but im hoping to also help people new to wrenching.

please note this is not a california model. they have additional emissions stuff.

step1. remove the side plastics to gain access to removing seat.
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step2. remove seat
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youll then be looking at this..
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step 3. remove gas tank
remove these 2 bolts at front of tank.
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remove this bolt at the rear of the tank.
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disconnect this line from the tank it will drip some and then stop.
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you can then prop up the tank with a 2x4 or something. i wound up taking the tank completely off eventually which is a little more involved but unecessary.
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you could also put something down on the tail and flip it around like this if your careful.
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if removing tank completely youll need to unplug this.
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and this
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now this next part, you dont have to completely take apart the airbox like i did but i figured id show it since im installing a bmc race air filter anyway.
step 4. removing airbox
unplug this.
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remove these 5 bolts and remove.
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remove all the screws in the airbox
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dont forget this one deep down in there hidden.
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disconnect this hose
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you should be looking at this now.
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remove this bolt towards top of pic by frame
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only allowed 20 images so this will be continued
 
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#2 · (Edited)
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.
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you should be looking at this now
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remove these bolts. theres 2 per plate.
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remove the plates and the hoses that are attached and the pair valve all as 1 piece.
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install these block off plates. i used ivans.
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this is the white plug you need to jumper. hard to see but i used a small staple.
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then tape it up.
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use this included vac plug to plug the bottom of the airbox
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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.
 
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#3 ·
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.
 
#13 ·
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!
 

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#4 ·
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?
 
#5 ·
#8 ·
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.
 
#10 ·
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.
 
#16 ·
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
 
#46 ·
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?
 
#53 ·
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?
 
#22 ·
this is the white plug you need to jumper. hard to see but i used a small staple.
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then tape it up.
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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
 
#23 ·
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.
 
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#74 ·
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!
 
#27 · (Edited)
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?
 
#28 ·
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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.
 
#31 ·
racing says u need to put it into a catch can though. a filter could blow oil every where
 
#33 ·
I love it! My bike runs so much smoother now. I recomend getting this to everyone. Thanks for the writeup!