Please Help, I would like an alternative way to replace the cali air system

Started by Richard Nixon, April 06, 2013, 12:34:34 PM

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Richard Nixon

So, I bought the bike back in January and discovered i have the 2005 California model.
I decided I would catch up on all the maintenance so i pulled the tank and found I am missing a lot of hoses and what not.
I don't have any intention on having the California secondary air system, because i dont live in cali and id rather not buy all the secondary stuff.
So I'm wondering what i actually need to have connected or filtered or let to the open air.
-Thank you
here is some pictures:

I believe this is the crank case breather and it should probably be connected to the airbox



I think the port on the airbox goes to the said crankcase breather 
But the left outlet on the carb is what im unsure of where that goes


These two little white ports were probably attached to the california vacuum system i think. But id rather not bother with that stuff unless i absolutely need it.
So im wondering what is the alternative to these, rather than replacing the original cali system?
-Thanks in advance

Zwerski

I'm interested to see the responses. My buddy has a CA model and he'd like to do away with the evap system and all the extra stuff

Richard Nixon

I'm thinking about having them all go to the airbox, maybe. Instead of leaving them to the open air, but I am unsure of what the outlet on the carb does or the smaller white ones :dunno_black:
I'm thinking i want to at least do that so they don't suck in any dirty air, but also if the one on the carb is some sort of vapor release then it would probably be a bad idea to let that out into the airbox.

weedahoe

Everything you have picture has nothing to do with the CA model.

The first pic is a hose that vents. Most of us (myself included) buy a small cone filter from an auto parts store and connect to the hose that goes on the nipple. No hose? No worries, any proper size hose will work.

Second pic, the nipple off the carb is vented also. See the link below. Nipple on the air filter box, if it were me (and I did do this) I would do away with the stock box and get a K&N Lunchbox air filter

Third pic, vac port and they MUST be used. Again, see link below

http://gstwins.com/gsboard/index.php?topic=56601.0
2007
K&N Lunchbox
20/62.5/142.5
chromed pegs
R6 shock
89 aluminum knuckle
Lowering links
Bar mirrors w/LEDs
rear LED turns
89 clip ons
Dual Yoshi TRS
Gauge/Indicator LEDs
T- Rex sliders
HID retrofit
GSXR rear sets
Zero Gravity screen
Chrome Katana rims
Bandit hugger
Custom paint
Sonic springs

Richard Nixon

Alright cool thanks.   :)  I figured that the canister would effect the hose routing.
I am really interested in the lunchbox filter modification now

skunkteeth

I have a 2006 CA model and I removed all that stuff along with replacing the carb tops with black tops. Much easier to work on. Lunchbox also and removed PAIR and evap canister


jestercinti

Don't have the carb vent go to the airbox.  Serch "Crosswind Engine Stumble" and "Hose routing diagram" to see how imprtant the fuel vent is.
Bikeless and Broke at the moment...

Richard Nixon

Quote from: skunkteeth on April 06, 2013, 11:41:02 PM
I have a 2006 CA model and I removed all that stuff along with replacing the carb tops with black tops. Much easier to work on. Lunchbox also and removed PAIR and evap canister

I think I may do the same, thank you.

Richard Nixon



Wait one second, i looked at the diagrams and such and i think im talking about the port that the diagram did not have. (the very top one) Is that also a second vent?
Also the one at the very bottom should be connected to the airbox, right?
Sorry for being such a noob
Thanks!

Richard Nixon

Quote from: skunkteeth on April 06, 2013, 11:41:02 PM
I have a 2006 CA model and I removed all that stuff along with replacing the carb tops with black tops. Much easier to work on. Lunchbox also and removed PAIR and evap canister

I feel like this is my best option. So with the black carb tops, there are less vacuum hoses?

skunkteeth

Yea the only hoses on my carbs is the vent and the tube for the fuel petcock. It will look like the lunchbox pic in the wiki

Richard Nixon

Quote from: skunkteeth on April 09, 2013, 09:31:26 AM
Yea the only hoses on my carbs is the vent and the tube for the fuel petcock. It will look like the lunchbox pic in the wiki

Cool. Would i have to replace anything else other than the top of the carbs?


adidasguy

I'm not sure what is happening here. Removing Cal. stuff was not that involned.

I removed the Cali stuff from a 2006 as I parted it out and put parts in other bikes.
Canister is the only thing unique to California: just disconnected it and capped off what it connected to. Tank has a connection to it you can cap off.

PAIR was separate item - not unique to California. Again there, I removed it and capped off the places it connected (one tube from the carbs, I think one to the airbox) and installed the PAIR block-off plates.

Replacing the tops of the carbs? Not sure why that is necessary. Nothing to do with CA. The extra stuff is for the timing and basic operation of the 2004+ ignition. There's a vacuum switch and throttle position sensor that connect to the ignition control unit. I guess you can replace the caps to make the carbs like the 01-02 models. Then disconnect the TPS and vacuum switch lines to the ICU as well. It is supposed to operate in a fail safe mode with those things not there. Not sure, but the neutral switch also has 1st and 2nd gear sensor which operates along with the TPS and vacuum switch. So not sure how the ICU will behave with that and not the TPS and vacuum switch.

There is a vacuum reservoir which smooths out fluctuations in the vacuum. I don't thing you should remove that.

Have I missed something in trying to follow this thread?  :dunno_black:

The black hose in the middle operates the PAIR system. Remove and cap off at the "T". Nothing on the carbs is California specific. Everyone has the PAIR system. The only CA specific thing is the "canister", which doesn't connect to the carbs.


You see the top vent goes to a small filter.
The lower vent has a long black tube that runs over to the back side of the air box and just sits there to the open air.
You can see the vacuum reservoir (upper left) that comes off the vacuum lines on the right.
The gray hose going off to the left goes to the petcock.


Richard Nixon

Basically me missing some stuff, and having no idea what to do with any of the open ports. And i was looking for some sort of solution

adidasguy

Go here to see detailed shots of a complete set of carbs from various angles. You can see all hoses and how they connect
http://s1206.photobucket.com/user/adidasguy/library/Technical?page=4


adidasguy

On the other pages of the technical area, you'll find photos as I was removing things from a bike and other shots that may be helpful.

Richard Nixon

Quote from: adidasguy on April 09, 2013, 05:10:42 PM
On the other pages of the technical area, you'll find photos as I was removing things from a bike and other shots that may be helpful.

Good, its exactly what im looking for. I find it strange that my service manual covers everything except this stuff.

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