This is a step-by-step tutorial to remove the PAIR (Pulsed Secondary Air Injection) valve. The PAIR valve is an emission control. Many racers and track riders remove this to save on weight and get rid of parts that are not absolutely necessary. Though this tutorial is shown on an '05 600RR, it will apply conceptually to all bikes. This tutorial uses standard hand tools.
Things you'll need (what is actually needed depends on how the PAIR removal is done):
- 5/8" vacuum plugs (at least one, as many as 3)
- silicone RTV
- PAIR block-off plates
[Click on any pic to view a higher-resolution version]
First remove all fairings such that you have access to the engine. In this case, this required the removal of the seat, lower and middle side fairings, air duct covers, and tank cover. It is possible to remove just the tank and air duct covers, if you're clever enough.
Remove the forward-most tank bolts. Pivot the tank back and suspend the tank. Here a small bungee cord is used to suspend the tank.
Remove ECM (Engine Control Module).
Disconnect the black 2P PAIR solenoid valve connector (A), IAT sensor connector (B), and the air cleaner cover.
Disconnect secondary air injector connectors and remove secondary air injectors.
Remove air filter and upper air cleaner housing.
Remove velocity stacks (C) and disconnect MAP sensor connector (D), vacuum hose to the MAP sensor connector, all hoses connected to the lower air cleaner housing, and lower air cleaner housing.
Disconnect PAIR control solenoid valve hoses (E) and remove PAIR control solenoid valve (F). There is a hose that connects the PAIR control solenoid valve to the lower airbox housing but this was already disconnected in teh previous step.
Plug the openings that remain from removing the PAIR control solenoid valve hoses with a 5/8" vacuum plug.
For a clearer picture, here is what it looks like with the heat guard rubber removed.
Because of the removal of the PAIR control solenoid valve, there is now an opening in the airbox that needs to be plugged as well. Use a 5/8" vacuum plug on the airbox opening. This opening can be plugged on the inside of the airbox (pictured below) or it can also be plugged on the outside (i.e. bottom) of the lower airbox housing.
Put everything back together and ride 
For those who want a more elegant solution, Kyle Racing offers block off plates for the top of the cylinder head cover. These would be used in place of the 5/8" vacuum plugs mentioned above.
[NOTE: the installation of these block off plates does not actually require removal of the cylinder head cover. Its done here for clarity]
Remove the PAIR check valve covers.
Use a small flathead screwdriver to pry out the PAIR check valve. (Note: there is a small Phillips screw on top of the PAIR check valve. You do not need to manipulate this screw in any way)
Removing the PAIR check valve will expose the PAIR reed. Remove the PAIR reed.
Apply a thin layer of silicone RTV to the edge of the PAIR check valve opening and install the PAIR block off plates. Torque to specifications (see service manual).
Acknowledgements: The author would like to thank Dan Kyle of Kyle Racing for his phone support on the proper installation of the block off plates.
 badfish'05 600RR Purple/Black |  |