Block-off install guide

Kawasaki ZX-10R

Air Injection System (smog) system block off plates

 

 

Block-off plates allow the removal off the Kawasaki AIS system installed for emissions reasons. Benefits off this are improved exhaust flow, minor weight savings, a cleaner and less cluttered engine area, a more stable A/F reading for more precise tuning on a Dyno and the elimination of backfiring or “popping” with aftermarket exhausts.

 

The following are some basic instructions to help you install your ZX-10R block off plates. It is recommended that you read these before attempting installation. If you are unfamiliar with your motorcycle it may be necessary to consult a workshop manual. The whole install should take around 2 to 3 hours depending on your ability and experience.

 

If you do not feel confident or are uncertain of your ability installing this product, it is recommended that you have your mechanic install them for you.

 

Make sure you have adequate room to work, suitable quality tools and all parts and supplies needed. You will need to purchase some gasket sealer such as RTV silicone and some blue Loctite.

1. You will need to remove your seat and tank. You may also find it helpful to remove the left, right and lower fairing.

2. Remove the entire air box, RAM air tubes and heat shielding. To remove the air box rotate it 90 degrees otherwise it will not clear the frame rails. It may be necessary to consult your workshop manual at this stage.

3. Use an Allen key to remove the Kleen system. It is located on the cylinder head cover. The picture below is what you need to remove. You may find it easier to remove the tubes and solenoid before removing the valve covers.

This step can be quite a challenge as there isn’t much room to work in.

4. Remove the inner parts of the valve. Clean the surface area where the block off plates will mate to the cylinder head cover.

 

5. Smear a thin layer of gasket sealer on the outside edges of the block off plates or alternatively leave the reed valves in place, they have a rubber seal that will seal your block off plates. Install the block off plates in place of the original valve covers using the bolts provided. Be sure to blue Loctite all the bolts and to reinstall the electrical plug mounting bracket on the left plate. Make sure the block off plates have seated properly. Avoid using to much gasket sealer, only a small amount is needed.

6. Reassemble all parts on the motorcycle. Remember to plug the hole where the Kleen valve was connected to the air box with the rubber plug provided. Failing to do so may result in reduced performance of your intake system.

 

7. Do not start the motorcycle until the gasket sealer has had time to cure. Consult the packaging of your sealant for curing time. Once sealant has cured start the motorcycle and check everything is working properly.

 

 

Congratulations!

If all went well your Mustard Bikes block off plates are now installed .