2024 ZX6R 40th Anniversary Edition: Delete Emissions, Preparation for Graves Full Titanium Exhaust

In today's video we’re removing the Exhaust Flapper Valve Servo Motor, Pair Valve, and Installing PSR Block-Off Plates along with a K&N Performance Air Filter. This is the 2nd of 5 videos leading up to a full Dyno Tune at Moore Mafia in South Carolina.

1. Disassemble Fairings
2. Delete Emissions
3. Install Graves Full Titanium/Carbon Exhaust
4. Reassemble Fairings
5. Dyno Tune/ECU Flash at Moore Mafia

Instructions with Time Stamps and Parts can be viewed in the Description below, or you can view and/or download these files from the NINJAof1 Google Drive at:
https://drive.google.com/drive/folder...

Leave a comment/question, also, Like, Share, Subscribe, and Ring that Notification Bell because there's much more great content to come. Thank you for tuning into the NINJAof1 YouTube Channel.

Follow the link below to view the entire ZX6R Build Series.

   • New 2024 ZX6R 40th Anniversary Editio...  

Instructions with Time Stamps:
1. Intro to Parts and Tools. 01:05
1. Remove Exhaust Servo Motor from Sub-Frame: 02:48
Loosen and Remove Exhaust Servo Motor Cables from Exhaust Servo Motor.
Remove 2 Small Bolts.
Disconnect Exhaust Servo Motor from Main Wire Harness.
Tape-Off Exhaust Servo Motor Connector on Main Harness.
2. Remove Upper Air Box: 03:35
Disconnect Air Intake Temperature Sensor from Upper Air Box and remove wire from side of Air Box.
Remove 8 Self-Tapping Screws and remove upper Air Box.
3. Remove Lower Air Box: 03:51
Loosen Throttle Body Clamp Bolts on Left and Right sides, 7 Full Turns should be enough.
Remove Throttle Cables Retaining Bracket from Top/Front of Lower Air Box and Frame, 1 Bolt.
Disconnect Crank Case Breather Hose on Left/Rear corner of Lower Left Air Box.
Disconnect Water Overflow Hose on Left/Rear corner of Lower Left Air Box.
Remove Air Filter.
Lift Lower Air Box from Throttle Bodies, DO NOT Remove Yet.
Disconnect Pair Valve Hose from Bottom/Right/Center of Lower Air Box and Remove Lower Air Box.
Disconnect Exhaust 02 Sensor Connector and route connector and wire back down right side of Bike.
Tape-off Exhaust 02 Sensor Connector on Main Wire Harness.
Dress up Cables and place Foam Cushions as necessary.
4. Remove PAIR Valve Plates/Hoses/Solenoid: 04:31
Disconnect Pair Valve Solenoid from Main Wire Harness.
Pull 2 Hoses from Pair Valve Plates.
Pull Engine Cover Seal back from the front.
Remove 2 Small Bolts for each Pair Valve Plate.
Remove Pair Valve Plates. Leave Pair Valve Reed Gaskets in place.
5. Install Pair Valve Block-Off Plates: 05:07
Install Block-Off Plates with existing Reed Valve Gaskets.
Install 2 Small Bolts for each Block-Off Plate.
Torque all 4 small bolts to 89 Inch LBS with Non-Permanent Lock Tight (Blue).
Put Engine Cover Seal back over engine.
Tape-off Pair Valve Solenoid Connector on Main Harness.
Ensure all cables and hoses are tucked away.
6. Install Lower & Upper Air Box: 06:13
Cap off and Zip Tie Air Outlet on Bottom/Right/Center of Lower Air Box.
Install Lower Air Box, 'Forward-Intake' first, then mount onto Throttle Bodies.
Ensure the inner walls of the Velocity Stacks and Throttle Body Tubes have no gaps and are smooth to the touch.
Torque Throttle Body Clamps on both sides to 13 Inch LBS.
Connect Crank Case Breather Hose under Left/Rear corner of Lower Air Box.
Connect Air Box Water Overflow Hose under Left/Rear corner of Lower Air Box.
Install Air Filter.
Install Throttle Cable Retaining Bracket at Front/Top/Center of Frame, 1Bolt.
Install Upper Air Box with 8 Phillips Head Self-Tapping Screws.
Connect Air Intake Temperature Sensor to Top/Front/Center of Upper Air Box.
Insert Air Intake Temperature Senso Wire onto Retainer at Right/Front side of Upper Air Box.
7. Install Fuel Tank. 07:39
Lay Fuel Tank in its original position.
Install Bolt at the rear of the Fuel Tank.
Prop up the Front of the Fuel Tank.
Remove Cap from Fuel Line.
Remove Cap from Fuel Outlet on the Fuel Tank.
Connect Fuel Line to Fuel Tank Outlet.
Lay Fuel Tank back into its original position.
Remove Cap from the Fuel Tank Overflow (Left) and Fuel Vapor (Right) Outlets.
Connect Fuel Overflow (Left) and Fuel Vapor (Right) Hoses.
Mount the Steering Damper Bracket over the top of Fuel Tank.
Install 2 Bolts on Steering Damper Bracket and Front of Fuel Tank.

Parts:
Description / Part Number / Manufacturer / Vendor
Block Off Plate, BLK / 0930-0098 / PSR / Kawasaki Suzuki of Rome
K&N Performance Air Filter / KA-6009 / K&N / Kawasaki Suzuki of Rome
Graves Full Titanium/Carbon Fiber Exhaust / EXK-19ZX6-FTCW / Graves Motor Sports / Kawasaki Suzuki of Rome