Kawasaki Ninja ZX-6R Forum banner

Time to rip stuff off!

3.5K views 33 replies 7 participants last post by  Corvus  
#1 ·
Ok, so after doing some research and bike inspecting I have confirmed that I have a CA model 09. These came with the crap emissions smog stuff and I want it gone.

I found this: CA model smog system removal + Kleen Air 09 zx6r : KawiForums.com Kawasaki Forums: Kawasaki motorcycle forums

While I'm in there I think I will do the Kleen Air mod and the air filter mod.

Am I doing this right? Will I severely screw up the bike hitting it with all of these mods? I'm just running it stock with an M4 GP.

Anyone with experience doing these mods or with feedback after completing them on an 09+ would be greatly appreciated. I feel like I may have a lot more bike hidden under emissions crap.
 
#2 ·
Oh also, if anyone can give me an idea of all of the hoses and fittings required to do the kleen air mod I would be much obliged. I already plan on getting some Driven block off plates on order.
 
#4 ·
#5 ·
I believe that you either do the kleen air mod OR the block off plates, as the kleen air mod utilizes existing parts while block off plates remove all that shit entirely. For either project, go pick up a pack of assorted vacuum line caps. If you wanna do the kleen air, pick up a few feet of heater hose and a T-fitting. Install the t between the 2 valve thingies on top of the motor, and use the new hose to route the T to the crankcase breather. Cap off the crankcase vent hole in the airbox as well as any other holes on the throttle bodies left from the parts removed, and call it a day.

If you do the block offs, leave the crankcase breather alone but still cap off the various vacuum ports.

PS I am a complete idiot that has no idea what he is talking about so please perform the above procedures at your own risk. That being said, I ran both of these setups for a couple thousand miles each with no issues. I also removed that bulky charcoal canister thing, I used the service manual to trace all the lines to properly remove that.
 
#6 ·
Cool thanks for some clarification. Every little bit helps. Whatever allows me to remove the most emissions and recycling air stuff is probably what I'd want to do. So plates and vacuum caps it sounds like. Plus removing the smog emissions CA thing I guess.
 
#7 ·
#9 ·
Yeah, I saw this thread and that's what got me wondering about my bike. Then when I was looking it up I remembered that my bike is a CA model and found out there is more I can take off. I'd just like a walkthrough like this for the 09 model clean air mod. I think the walkthrough I have is usable for getting rid of the Cali smog stuff.
 
#23 ·
gilby is completely wrong :lol:

staple thing = jumper mod. useless on 09+

kleen air = block off plates

ram air mod = gutting foam from inside intake
Could have sworn I read that you needed a staple for the kleen air mod on the later bikes. My bad.

HOWEVER, technically if you use block off plates, your not modding the kleen air at all. Your just removing it entirely. I was under the impression that kleen air mod was specifically rerouting the crankcase breather to the reed valves on top of the motor, instead of recycling it back into your airbox. Something about how the crankcase ends up with negative pressure, potentially creating ( a very very small amount of) horsepower. Block off plates DO NOT do that, as you either have to leave it routed to the air box, or cap it with a little filter like all the civic guys with cold air intakes do.
 
#12 ·
gilby is completely wrong :lol:

staple thing = jumper mod. useless on 09+

kleen air = block off plates

ram air mod = gutting foam from inside intake
 
#13 ·
Yes! Thank you for some clarification. So really, I should get a couple vacuum caps to cover the CA stuff and get some block off plates for the kleen air. Then just gut the ram air while I'm in there.
 
#14 ·
Do the smog block offs.... then remove the entire smog system. Only things you'll need to leave connected are the crank case rebreather hose going up to the airbox. ANd the small oil overflow catch from the left side of the airbox. The rest of the smog shit can be pulled out. I have ZERO immissions crap on my bike now.
 
#15 ·
#16 ·
No... the crank case rebreather is on the back of the airbox and routes pretty much straight down into the crank case. It's a pretty large hose actually... can't miss it. Has probably a 2/4 inch hose. You should be able to see it even with the fairings on the bike.
 
#18 ·
Ok yeah I know what you're talking about. I'll follow up with the service manual and track all of the pipes. So basically, my shopping list should be a set of block off plates, and 3/8" vacuum cap for the airbox and 1/8" for capping where CA emissions pump attaches to the radiator?
 
#20 ·
Cool thanks PG big help. Can't wait to dump this extra crap :D:
 
#21 ·
It's a really easy job to be honest. Just take your time. Enjoy!
 
#22 ·
Ok last question I swear :tounge2:

This shouldn't give me any issues running everything stock right? I won't be running too lean with the added air from doing all of this? All I have is an M4 slip on and no PC.
 
#24 · (Edited)
i have an 09 as well and i have removed all the smog crap it back. to get rid of it all you will have to take off the charcol canister its inside the left fareing. if you follow the how to guide it should go smooth it will make her run much smoother but the only down side is you loose some mpg but it was worth it to me if you get it tuned you will get most of it back. oh on the tank i capped the red and ran the blue down under the bike next to the other vent if you cap both you will smell fuel all the time i dont know why you just do hope this helps
 
#27 ·
if you follow the how to guide it should go smooth it will make her run much smoother but the only down side is you loose some mpg but it was worth it to me if you get it tuned you will get most of it back.
Did you really lose mpg? I would imagine you would actually gain mpg by allowing the block to get more fresh air and not have to cycle it around between the smog system and between the reeds. I understand that you may have to have it tuned, but it did run better than stock after you removed it without it being tuned right?

You sure you just weren't more liberal with the right wrist after it was running better? :devious
 
#25 ·
kleen air is making the bike unable to recycle old used air. instead of the recycled air recirculating through, it is now all fresh air(kleen). the little smog setup just gets removed. since it is gone, you just use block offs and plugs to keep everything flowing straight through instead of taking a pit stop where it was originally getting recycled.

only stapling i've heard of is for the jumper mod. which we don't get benefits from.


i have no emissions on my bike. i even gutted the headers.
 
#28 ·
yes it ran much better but i lost some mpg for sure the way it was explaned to me was that the canister held unburnt fuel to be recerculated back into the system. i got 113 miles til the light came on before i did this mod and now i get 98 to 99 miles. i was told this would happen before i did it so i was not shocked when it happend id say try it if you dont likr it you can put stuff back. sorry for bad spelling
 
#29 · (Edited)
also i did not use block off plates i just took off the pair valve and put large vacume plugs on with hose clamps. six bucks and just down the road from me but i may get some later on oh if you remove the bracket to the canister in your right faring make sure you put the screws back in one of them is to your blinker.
 
#30 ·
also i did not use block off plates i just took off the pair valve and put large vacume plugs on with hose clamps. six bucks and just down the road from me but i may get some later on
Yeah, I've got vacuum caps that would work. I just think I'd prefer the cleaner look of blocking it off if there is nothing bad that will happen. Gonna be capping off all the smog stuff in there anyways. Hope I won't lose too much mpg.
 
#32 ·
Oh yeah it's happening for sure no question. That's pretty much objective one for any motorized vehicle of mine is to have it free breathing. Any manifold obstructions, lack of cool air intake, or emissions requirements have to go. Also a big one for free exhaust with just the right amount of back pressure. All of this smog stuff is going ASAP lol
 
#33 ·
i get 120 miles before my light comes on. about 39-40 mpg. no emissions stuff. no cat. TB short pipe. TB Juice Box
 
#34 ·
Wow nice. I think right at 40 is where I am now. Bought 45-50ish mile ride and I was down 1.2 gallons I think. I'm still pretty convinced taking the stuff off would improve your mpg. Especially if you're running straight pipes with a fuel map and getting those numbers.