How To remove KLEEN / AIS for Cal / 50st bikes - Kawasaki ZX-10R.net
 
LinkBack Thread Tools Display Modes
post #1 of 148 Old 04-18-2004, 06:35 PM Thread Starter
I really need to get out of the house
 
Big Daddy's Avatar
 
Join Date: Dec 2003
Posts: 34,537
Posting Frequency
Images: 38
           
How To remove KLEEN / AIS for Cal / 50st bikes

:)
The following instructions are not detailed to the extent some would like but they are sufficient enough to get the job done for the vast majority.


KLEEN /AIS removal procedure:

It's a pretty straight forward job using some basic tools once the seat, black side panels (2), gas tank, and both side body panels are removed for easy access to the solenoid, charcoal canister and associated hoses, it does of course require removing the airbox, and that itself requires an interesting method as the airbox is shoehorned into the spars and can be rotated counter clockwise in conjunction with pushing the rubber air intake boots forward making for the necessary room to remove it.

To remove the AIS/KLEEN solenoid, you’ll need the following:
(1) 5/8th vacuum cap (primary solenoid feed from airbox base plate)
(2) 3/8th vacuum caps (or appropriate reed block off plates)

To remove the charcoal canister (and related hardware), you’ll need the following:
(2) 1/8th vacuum caps for throttle body lines.
(1) 3/16th vacuum cap for the red tank inlet located in the upper RH corner of tank when in place (charcoal canister/fuel tank feed – 1/4th caps may be applicable)
(1) suitable hose (reuse the hose with a blue stripe) connected to the blue tank inlet located in the upper RH corner of tank when in place and routed inside the RH frame rail and across the backside of the throttle bodies, then insert a 'T' fitting into it which accepts the OEM tank vent hose and a reused portion of a KLEEN canister hose connected into the other end of the 'T' fitting and run it down alongside the motor so it hangs down below so the tank vents properly.

Band / compression clasps, zip ties, hose clamps throughout (where applicable), are essential in order to seal the vacuum caps.

Heres 1 pic of the charcoal canister and ais pump after removal.

BD
Attached Thumbnails
Click image for larger version

Name:	kleen-ais-pic.JPG
Views:	476
Size:	53.8 KB
ID:	246074  

Those who stir the shit pot should have to lick the spoon.
Big Daddy is offline  
Sponsored Links
Advertisement
 
post #2 of 148 Old 04-18-2004, 07:34 PM
GP Star
 
CanyonCarver's Avatar
 
Join Date: Apr 2004
Location: SoCal
Posts: 2,023
Posting Frequency
  
Cool. Thanks for the information, BD. FWIW, Dan Kyle has the block-off plates. They are the same as the 636 plates and under $30. Just got mine in the mail this week, but will install this week.
CanyonCarver is offline  
post #3 of 148 Old 04-18-2004, 07:39 PM Thread Starter
I really need to get out of the house
 
Big Daddy's Avatar
 
Join Date: Dec 2003
Posts: 34,537
Posting Frequency
Images: 38
           
Yeah the plates are by far the cleanest setup but using the plugs gives the same results so its nice to have a choice.

BD

Those who stir the shit pot should have to lick the spoon.
Big Daddy is offline  
 
post #4 of 148 Old 06-09-2004, 04:11 AM
GP Rider
 
vane's Avatar
 
Join Date: Jun 2004
Location: Tzaneen, Northern Province, South Africa
Posts: 1,342
Posting Frequency
 
Re: KLEEN / AIS removal procedure for Cal / 50st bikes

Quote:
Originally Posted by Big Daddy
:)
The following instructions are not detailed to the extent some would like but they are sufficient enough to get the job done for the vast majority.


KLEEN /AIS removal procedure:

It's a pretty straight forward job using some basic tools once the seat, black side panels (2), gas tank, and both side body panels are removed for easy access to the solenoid, charcoal canister and associated hoses, it does of course require removing the airbox, and that itself requires an interesting method as the airbox is shoehorned into the spars and can be rotated counter clockwise in conjunction with pushing the rubber air intake boots forward making for the necessary room to remove it.

To remove the AIS/KLEEN solenoid, you’ll need the following:
(1) 5/8th vacuum cap (primary solenoid feed from airbox base plate)
(2) 3/8th vacuum caps (or appropriate reed block off plates)

To remove the charcoal canister (and related hardware), you’ll need the following:
(2) 1/8th vacuum caps (throttle body lines)
(1) 3/16th vacuum cap for the red inlet (charcoal canister/fuel tank feed – 1/4th caps may be applicable)
(1) suitable hose (perferably the hose with a blue stripe) connected to the blue inlet and routed inside the RH frame rail and across the backside of the FI bodies, then insert a 'T' fitting into it so that the tank vent/overflow hose can be connected into the other 2 ends so the tank vents properly.

Band / compression clasps, zip ties, hose clamps throughout (where applicable), are essential in order to seal the vacuum caps.

Sorry no pics as i don't have a digi. :(

BD
My doctor said that I'm allowed one stupid question per day, so here's today's question.

What is the AIS / KLEEN? What does it do and why do you remove it?

I know nothing about bikes!
vane is offline  
post #5 of 148 Old 06-09-2004, 08:59 AM
GP Rider
 
dnwhoop02's Avatar
 
Join Date: May 2004
Location: College Station, TX
Posts: 1,262
Posting Frequency
Images: 8
 
Are there any ill effects of using the block off plates? The KLEEN system is just an emissions control component, so disabling it won't affect performance or anything, will it?

David Nolden
CMRA #711
dnwhoop02 is offline  
post #6 of 148 Old 06-09-2004, 10:09 AM Thread Starter
I really need to get out of the house
 
Big Daddy's Avatar
 
Join Date: Dec 2003
Posts: 34,537
Posting Frequency
Images: 38
           
Quote:
Originally Posted by dnwhoop02
Are there any ill effects of using the block off plates? The KLEEN system is just an emissions control component, so disabling it won't affect performance or anything, will it?
The plates would be the better setup if you have them or plan to purchase them (at the time they were not available yet so......) The disconnecting of the KLEEN components will not effect performance.

BD

Those who stir the shit pot should have to lick the spoon.
Big Daddy is offline  
post #7 of 148 Old 06-12-2004, 11:12 PM
Street Rider
 
Turtle's Avatar
 
Join Date: Jun 2004
Location: Aurora Co.
Posts: 84
Posting Frequency
 
Thanks more usefull info.

95' ZX9R
02' GSXR600 Race(sold)
03' YZ450F(sold)
04' ZX6RR Race
04' ZX10R
08' ZX10R
03'-04'WSMC #716
MRA #716
Turtle is offline  
post #8 of 148 Old 06-14-2004, 09:37 AM
GP Rider
 
dnwhoop02's Avatar
 
Join Date: May 2004
Location: College Station, TX
Posts: 1,262
Posting Frequency
Images: 8
 
Quote:
Originally Posted by CanyonCarver
Cool. Thanks for the information, BD. FWIW, Dan Kyle has the block-off plates. They are the same as the 636 plates and under $30. Just got mine in the mail this week, but will install this week.
have you installed these yet? If so, did they do the trick?

David Nolden
CMRA #711
dnwhoop02 is offline  
post #9 of 148 Old 06-14-2004, 01:44 PM
GP Star
 
CanyonCarver's Avatar
 
Join Date: Apr 2004
Location: SoCal
Posts: 2,023
Posting Frequency
  
Quote:
Originally Posted by dnwhoop02
Quote:
Originally Posted by CanyonCarver
Cool. Thanks for the information, BD. FWIW, Dan Kyle has the block-off plates. They are the same as the 636 plates and under $30. Just got mine in the mail this week, but will install this week.
have you installed these yet? If so, did they do the trick?
Yep, and yep. :)

A pic for your viewing pleasure:

CanyonCarver is offline  
post #10 of 148 Old 06-14-2004, 02:09 PM Thread Starter
I really need to get out of the house
 
Big Daddy's Avatar
 
Join Date: Dec 2003
Posts: 34,537
Posting Frequency
Images: 38
           
those look like pics of a pw 50 :P

BD

Those who stir the shit pot should have to lick the spoon.
Big Daddy is offline  
Sponsored Links
Advertisement
 
 

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki ZX-10R.net forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome