Removing the 'Kleen' system from a 2000' ZX9R - Sportbike Forum: Sportbike Motorcycle Forums
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post #1 of 15 (permalink) Old 09-30-2005, 02:39 AM Thread Starter
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Removing the 'Kleen' system from a 2000' ZX9R

can anyone tell me the correct way to remove the California emission system. I have a bike that I bought with the canister removed and need to verfiy that all was done correctly.

I've got a flooding problem that so far have not been able to figure out. I've replaced all the float valves, adjusted the float heights, checked most of the bikes hardware out and it still floods.

The bike runs and idles perfect once started, but noticed fuel pooling up on butterflies when bike is hot and parked after riding.

When float bowls are empty, bike starts right up with no smoke from exhaust. The smoke when it happens, smells strong of fuel.

All diaphrams in carbs are perfect and floats are not cracked. all jets are tight and cleaned up carbs. Bike did this when I bought it. Bike has a Muzzy header and K & N filter.

All hoses are there for vacuum valve and vacuum switch. Vacuum valve tube which went to breather and canister is plugged off. Gas tank rear where it was connected to the canister is connected together between 1 and 2 tank tube. Reed valves are still connected to the vacuum switch.

No hoses pinched either.

Thanks!

Last edited by rosalk; 09-30-2005 at 09:01 AM.
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post #2 of 15 (permalink) Old 09-30-2005, 04:43 PM
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Re: Removing the 'Kleen' system from a 2000' ZX9R

Quote:
Originally posted by rosalk
Gas tank rear where it was connected to the canister is connected together between 1 and 2 tank tube.
Thanks!
I've been thinking about this a little since last night...Seems that it is unlikely that the gas is coming through the pump/float bowl route, so that leaves this assembly right here.

Run your bike as usual, and then pull these lines & see if they are flowing gas. Kinda have the feeling they might be.....
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post #3 of 15 (permalink) Old 09-30-2005, 06:35 PM Thread Starter
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I was trying to put a picture in, but couldn't figure that one out.
Their are (3) hoses on the rear of the tank, just under the seat. One is a drain hose and the other (2) were for the emission hookup. It should be about the same as your tank overflow hose, but there are (2) more there.

I you e-mail me at rosalk@bytehead.com I will have your e-mail and can send you some pictures.

Thanks!
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post #4 of 15 (permalink) Old 10-02-2005, 04:41 AM Thread Starter
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Found it

I found the correct way to remove the clean system extra parts, see picture.
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File Type: jpg kleen system removal.jpg (61.2 KB, 126 views)

Last edited by rosalk; 10-02-2005 at 04:45 AM.
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post #5 of 15 (permalink) Old 10-03-2005, 12:12 AM
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That's a ZX12 frame, but I suppose the plumbing is the same..Let me look at my manual, and see what it says......

I spent a good deal of time looking at my manual...There is little info about the Cali plumbing... In the pictures you posted, none of the parts shown relate to this plumbing...additionally, the 12 is a fuel-injected bike with a high pressure pump. Yours is a carb bike with a low pressure pump, similar to a ZX11.

Clear this up for me - I'm not sure what you are saying here....."Gas tank rear where it was connected to the canister is connected together between 1 and 2 tank tube" Does this mean that the two tubes leading from the gas tank are now connected together?

Let me put it another way...Are you absolutely certain that there is no connection between the fuel tank and the manifolds other than the fuel line which goes to the fuel pump?

Last edited by Rundog; 10-03-2005 at 12:53 AM.
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post #6 of 15 (permalink) Old 10-03-2005, 02:41 AM Thread Starter
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Yes, the rear of the fuel tank and not the bottom where the petcock is are connected together. See picture;

There are no other hose besides this and the fuel hose going to the fuel pump. That's it.

I have looked all over for directions on removal of the California emission system and had read about the details of connecting the reed valves together and removing the vacuum valve switch hose from the airbox but was not quite sure if all I read was correct. While doing a search on the 2000' model, I came up with this and the hardware for the vacuum valve switch listed is identical.

I started the bike last night and initially with float bowls dry it seemed to start a bit harder. Almost like the choke was not giving out as much fuel. After starting it sounded real good at all rpm's.

Did not take for a ride, but let it warm up real good. Turned off the bike and let it sit a few minutes. Bike started up and flooding while starting seemed a little better.

Hope this was the right thing to do.

thanks,
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File Type: jpg tank hoses.jpg (233.4 KB, 87 views)

Last edited by rosalk; 10-03-2005 at 02:49 AM.
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post #7 of 15 (permalink) Old 10-03-2005, 11:41 AM
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Alright, tell me if I'm seeing this right....Starting from the left, it seems that #1 & #2 are connected together by a kinked hose. Where does #3 go?
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post #8 of 15 (permalink) Old 10-03-2005, 03:16 PM Thread Starter
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#3 is the overflow that just hangs down to the bottom of the bike like most bikes have.

I was able to take the bike to work today. It seems that the problem may be resolved. I put a few gallons of gas in, walked in and payed for the gas came out and started it up without any problems. Bike didn't smoke or smell like fuel either. I have never been able to start it (after bike is warmed up or hot and waiting a few minutes) without giving full throttle, and holding the starter button in for about 1 minute with fuel smelling smoke coming out.

After work when I started it it had no smoke and started normally.

The bike also previously would sound like it was breathing after it was hot and parked. This was the fuel on top of the butterflies getting sucked in and then bubbling up. Tonight there was also no breathing noise.

I will keep an eye on it for a few days and see how the starting/flooding issue turns out.

I also did have the vacuum switch somewhat checked, and it seemed 'OK'. It took about 40lbs. of pressure to move the switch.

Let me know what you think.

Thanks!

Last edited by rosalk; 10-03-2005 at 03:18 PM.
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post #9 of 15 (permalink) Old 10-03-2005, 03:33 PM
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Glad to hear it....

Just out of curiosity, how old is your battery?
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post #10 of 15 (permalink) Old 10-03-2005, 04:47 PM Thread Starter
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The batteries dated 02' amd it holds a charge real good. I'm supprised because of all the cranking I had to do to start the thing most times. I've only dove this thing about a dozen times since July 1.

I just went out to start it after 3 hours of sitting. Petcock was left on. Bike started with no choke but a 'little' twist of the throttle. I was supprized!

I received an email from someone else on this topic, he mentioned this;

you need to make sure that the vacuum ports on the lower part of the intake track have been plugged also

Is this meaning the "rear of the cylinders under the carbs"?

#2 & 4 hoses from rear of cylinder went to valve switch and were plugged off last night. (vacuum switch removed)

Should #1 cylinder hose be plugged also? And intake of vacuum valve?

Last edited by rosalk; 10-03-2005 at 04:54 PM.
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