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1st, I'm not 100% sure this is the correct way, only way, or best way to do this. I'm hoping others who have done it will post up any mistakes or tips.

I'm not responsible for what you do to your bike. :roll:

This guide does not explain how to remove the tank/airbox.

Here's what you'll be removing: I'm told that unplugging the canister and the piece the block off plates replaces could throw codes. You can either jump the wires or do an ECU flash.





Here's the canister:
We'll be removing the Green hose and running the blue hose to the ground.



Trace the Green hose, you'll notice it T's off and connects to the throttle bodies. All these will be removed & the throttle bodies will be capped.



View from Front of bike to rear of bike:



View with hose removed & the 1/8" caps on:



Run the BLUE hose to the ground/catch can:



The manual shows a 'Catch Tank' that's on the non-CA models that I plan on ordering:



BLOCK OFF PLATES:

Remove the OEM piece shown here & install the block off plates:
NOTE: You'll want to cap the airbox where the larger hose went.



Here it is traced in RED:

 

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fantastic writeup! glad you got it all figured out!
 

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Great write up!

Just an FYI, removing the Charcoal Canister causes a check engine light. You must modify in ECU or do some type of jumper mod on the plug to prevent this.

And you have to really take care of what you do with that breather hose. I did the Charcoal canister delete on my Triumph and the remaining breather hose would leak fuel. Like mentioned by the OP, that catch can might be the best way to go.

You can also just cap the green hose to the throttle bodies when you pull it out of the charcoal canister if you don't mind the hoses being there. When I go to the track, I plug the hose with a spare battery screw and then tape it with blue tape. Obviously for a more permanent application you can do the same with electric tape but it must be plugged since it is a vacuum hose and will shoot dirt and debris into your throttle body.
 

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Discussion Starter #4 (Edited)
fantastic writeup! glad you got it all figured out!
Thanks man!! Thanks for all your help!

Great write up!

Just an FYI, removing the Charcoal Canister causes a check engine light. You must modify in ECU or do some type of jumper mod on the plug to prevent this.
Thanks for the reminder about the codes!

EDIT: Found out CA and non-CA models have the same gas cap.
 

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Thanks man!! Thanks for all your help!



Thanks for the reminder about the codes!

I was told the gas tank cap on the CA models is different too. The non-CA model gas tank caps vent air, but the manual shows the same 2 hoses on the bottom of the gas tank for the non-CA model, so I'm not sure about that.

I'm wondering if I use a gas tank cap like the Vortex ones that vent, if I could just plug the the tank where the blue breather hose goes and get rid of the hose and not have to get that catch tank.
I'm not exactly sure either. All I know is after I removed my Charcoal canister off of my triumph, I started having "vacuum" issues with my bike and started leaking more fuel and my fuel mileage was noticeably less. One time at the track, I had a pretty decent pool of gas in my track fairing.

I eventually completely plugged the breather hose that went into the Charcoal canister and it seemed to fix it but my gas cap was always hard to open and I would always have a pressure release when opening it. I never dealth with it further before I sold her but there was obviously something else I should've done or something wasn't venting properly.
 

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my non-CA model '13 zx6r vents through the gas cap. i can hear it whining on particularly hot days.
 

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And if you do a jumper mod on the plug, post a DIY on that. I'll probably follow suit with removing the Charcoal Cannister. Tired of having the CEL light on when I go to the track.
 

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i've never dissambled it. i just hear it whining from time to time. page 164 (3-76 Fuel System (DFI) ) details the fuel tank and cap inspection and mentions air vent holes in the tank cap. Page 165 mentions the Evap control system on CA models and how the vapors from the fuel system (including gas tank) are routed back through the system.
 

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does your cap have the vents labeled "D" from this screengrab?


looks like non-CA models vent tank fumes directly into the air via the cap.
 

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i've never dissambled it. i just hear it whining from time to time. page 164 (3-76 Fuel System (DFI) ) details the fuel tank and cap inspection and mentions air vent holes in the tank cap. Page 165 mentions the Evap control system on CA models and how the vapors from the fuel system (including gas tank) are routed back through the system.
Thanks! Bookmarking this post and I'll check it out if I decide to do the delete.
 

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Discussion Starter #14 (Edited)
It looks like the Breather and Drain hose route inside the tank up to the cap. (See Yellow/Blue highlights). The photo below shows my cap & it matches the cap in the manual. CA models just need part "14069" & to route hose "B" to the ground.

 

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Thanks a lot for this write up! I have been looking everywhere for this. Do you think it would be a viable option to just replace the cap with, for example, a vented Vortex or driven cap? Also, how are you getting around the error codes? :idea
 

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Thanks a lot for this write up! I have been looking everywhere for this. Do you think it would be a viable option to just replace the cap with, for example, a vented Vortex or driven cap? Also, how are you getting around the error codes? :idea
I connected the wires on the EVAP valve harness together and didn't get any codes.
 

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You can stick a 100ohm resistor where the old KLEEN Air valve went and it wont throw a code. or some people block the system but leave the valve connected to the harness.

I'll get this thread moved to the How Too section.
 
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