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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
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
Those who stir the shit pot should have to lick the spoon.

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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.
I really need to get out of the house
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
BD
Those who stir the shit pot should have to lick the spoon.

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GP Rider
Join Date: Jun 2004
Location: Tzaneen, Northern Province, South Africa
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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
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
What is the AIS / KLEEN? What does it do and why do you remove it?
I know nothing about bikes!
GP Rider
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
CMRA #711
I really need to get out of the house
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?
BD
Those who stir the shit pot should have to lick the spoon.

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
02' GSXR600 Race(sold)
03' YZ450F(sold)
04' ZX6RR Race
04' ZX10R
08' ZX10R
03'-04'WSMC #716
MRA #716
GP Rider
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.
David Nolden
CMRA #711
CMRA #711
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.
A pic for your viewing pleasure:

I really need to get out of the house
those look like pics of a pw 50 :P
BD

BD
Those who stir the shit pot should have to lick the spoon.

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