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Discussion Starter #1
Hi All,

I've got a 02 zx6r California model. This model is different from the 49 other states, because it has extra emissions hardware in it. In other words, there is a LOT of extra crap in my bike, taking up space, and making it difficult to work on. I'd really like to remove this system completely.

This is NOT the same thing as the Kleen Mod for the zx6r. I have searched, but have not found a how-to for removal of the evaporative emission control system.

Here is a page from my service manual, showing the difference between the regular zx6r, and the CA model. The regular zx6r just has the normal petcock, fuel filter, and fuel pump. In the boxed area in the diagram, you can see just how much extra junk is in the CA model.


Here is another page which sheds more light on some of the connections of the CA model parts vs regular.



I think removal should just be a matter of taking out all the extra parts, and pluging or connecting the holes that are left over. I'm not sure if I can figure that out on my own. Anyone done this mod before? Any/All help would be awesome.

Thanks!
 

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Discussion Starter #2
After taking a lot of pics, and comparing the CA model to non-CA models, I think I may have found out how to do this.


Here is the separator which will be removed, it connects to the canister which will also be removed. The lines which come from the gas tank will be plugged. There is one line which goes to the left carb, and it will be removed and plugged at the carb.


Here are the lines coming from the carbs. All will be plugged.


Here is the carb hose which is already plugged


Here are the carb vent hoses which are currently connected to the vacuum valve. Vacuum valve will be removed and carb vent hoses will be routed outside.


Here is how my carb vent hoses will be routed


Another shot showing the vacuum valve and 2 of the 4 carb hoses which will be plugged.


Here are the components that are taken out during the kleen mod. Removing my evaporative emission control system will involve taking these out as well. Note that these components are included in non-CA models.


A close up of the previous picture


Let me know what ya'll think. I'm actually feeling pretty confident about this now, will let you know how it all turns out.
 

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Discussion Starter #3
Okay, so I busted out the rest of the emissions removal this afternoon/evening. Here are the progress pics.


Here is that huge canister which got totally removed


Here is the separator and tubes which went to the canister, all got removed


Look at all that space!!


Here is where I should mount smog block off plates, but guess what?? nobody sells 02 zx6r plates anymore... people say they do, but all pictures of their products show square plates.


Mine are clearly not squares... solution?


Tada! It was free and I didn't have to wait for shipping!


Capped off the airbox hole


Capped off gas tank holes


Also while the carbs were out, I gave them a good cleaning.

Threw it all back together ANNNNNNND, she won't start. Tries to, but no ignition. I think this is because fuel is not in the float bowls from the carb cleaning. Ran out of time so I couldn't test this theory, but will check it out tomorrow.
 

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sounds like that is probably the cause, double and triple check everything just to be sure.
 

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Discussion Starter #5
Good news! Went out to work on the bike today to see if I could look at that possible "no fuel in the float bowl" problem. But before I took it all apart again I thought I'd give it one more try, and after a couple coughs, she lit right up! Took her on a quick little victory lap too since snow is supposed to be on the way tonight.

So - I'd like to announce the successful removal of my evaporative emissions control system!

Here's a pic of all the crap that came out
 

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Discussion Starter #7
hey i have a 96 model but carby not fuel injected, have you had any problems from running the carby vent hoses to the outside
Really glad you asked that question. It actually was running a little weird with the carb vent hoses just left to vent outside, did a lot of searching and have found that the carb vent hoses should be equalized with the airbox. This is a very very easy fix:

Take a T junction, hook it up to the carb vent hoses, and run the tube to the hole in the airbox that is leftover from removal of the other emissions stuff. (I had capped it in the above pictures, but just removed the cap and hooked up the carb vent hoses)

Will post picture soon.
 

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Discussion Starter #8
Okay folks, here is how the carb vents should be routed. This WILL make a big difference in how your bike runs. Make sure you do it.

 

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Ironically, when I'm in the market for a bike, I specifically want one with all the gasoline vapor recovery equipment intact, won't even consider one that's been modified or that doesn't come with it. And here all you guys are gutting the stuff out.

I know I'm in the minority, but I have my reasons. And I prefer it that way. :rolleyes
 

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I was gonna say, the carbs should be vented to the airbox if you have any kind of ram air. This makes sure you have equal air pressure on both sides of the carb.

As for wanting the kleen air stuff on the bike, I was with you for a minute. Until I removed it all.

As it turned out I didnt even have half of it to begin with and the air valve wasn't hooked up to anything.
 

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Discussion Starter #11
Ironically, when I'm in the market for a bike, I specifically want one with all the gasoline vapor recovery equipment intact, won't even consider one that's been modified or that doesn't come with it. And here all you guys are gutting the stuff out.

I know I'm in the minority, but I have my reasons. And I prefer it that way. :rolleyes
To each their own, absolutely! But, just to make sure it's clear, 90% the stuff I removed was ONLY on California bikes. Every bike from every other state did not even come with this hardware when it rolled out of the factory brand new. This, to me, means that it's just junk added to meet California's ridiculous standards.
 

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Discussion Starter #12
As for wanting the kleen air stuff on the bike, I was with you for a minute. Until I removed it all.

As it turned out I didnt even have half of it to begin with and the air valve wasn't hooked up to anything.
Gotta love those crazy ignorant PO's dontcha? :tard
 

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... 90% the stuff I removed was ONLY on California bikes. Every bike from every other state did not even come with this hardware when it rolled out of the factory brand new...
I thought that was true, but for some reason you'll find bikes with the CA emissions equipment sprinkled throughout the country. Maybe leftover models being shipped all over, I guess. Christy's 7R and several other guys on here from Florida have them and so too do some of the people in Illinois, like Hammerhead's old ZZR, so your thread can have implications/benefit to other owners throughout the country.

Sorry about the threadjack, but I'm bored late at night. :evil
 

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I still think my 7 was a CA model. I had a long ass hose running up from the kleen air stuff to the subframe with nothing at the other end. Ive got the bracket stuff under the tail that holds it all, and I have obviously cut off bits of hose still on the tank/capped off.
 

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Discussion Starter #15
I hear that! I'm one of em! Bought and registered in Denver, but originally came from CA. Methinks this thread is done anyways =D Nothing left to do but shoot the shit here.
 

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Should be stickied.
 

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Looking at your gas tank...

Why did you cap the blue hose from the gas tank? I'm sure thats a vent for a flutter valve if the pressure in the tank gets too high...

Can anyone verify this? All bikes I have seen with the smog system removed leave a vent hose on the blue side of the gas tank.
 

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Discussion Starter #18
Looking back at the service manual diagram, it looks like you are right about that. Will unplug the blue guy.
 

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Looking back at the service manual diagram, it looks like you are right about that. Will unplug the blue guy.
Glad I could help out and prevent you from spontaneously exploding:blob Now where's my beer? lol
 

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I just pulled all that crap off my 96 model track bike. my brother a mechanic and put me on to running the vent hose to the airbox but i ran mine back to the top and seems to run fine so far
 
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