Valve Removal Method - Original 2012 Build
- Take a spare injector and a length of 5/16″ vinyl tubing.
- Heat one end of the tubing in hot water and slide it onto the BIG end of the injector.
- Fill the tube with water and slide the second end onto the other side of the injector
- (I use zip ties to “lock” the tubing on.)
- Plug this into the loom where you would have normally plugged in the injector.
- Place it such that any air bubbles will be at the top
- You’ll need to plug the header on the dead cyl to keep the engine from sucking exhaust gasses and carbon back into the engine and airbox. I used a freeze plug to do this.
- I first brushed out the header pipe, then cleaned with a solvent
- Tap the plug down into the header a ways. Its easy if you push it in sideways, then use a long screwdriver to turn it square and then finally tap it with a hammer handle to set it.
- Glue it in with high temp RTV
- (Pic is with LV header pipe)
How to build a 450 triple, original version
I turns out there are a few ways of doing this, so this is the original way
***All of these instructions are for the 2004/5 Suzuki GSX-R 600***
Your build will parallel this but may have some differences.
Also, make sure you understand what you’re doing. I’m doing this to both promote the concept and to help to create a self help of sorts for those of you who want to try it. I accept no responsibility nor liability for things going wrong.
The 4-Valve removal build:
1– remove your engine
2– remove your cylinder head
3– remove all four valves from the cylinder you wish to disable (we use cyl #2)
4– clean the valve guides well and fill with RTV type silcone sealer. It’s a good idea to wait 24 hours before trying to run the engine so the silicone can cure.
5– reinstall the cylinder head. you may wish to have the head “decked” or ‘skimmed” or run a thinner than stock head gasket
6– reassemble the rest of your engine. You may wish to degree your cams while you’ve got it all apart
7– when re-installing the exhaust, put a plug of sorts into the exhaust header of the dead cylinder (see pic)
8– leave the spark plug hooked up and installed in the head on the dead cylinder
9– disconnect the fuel injector for the disabled cylinder from the throttle body. Make and install a “dummy injector” and hook this dummy to the harness. This will make the computer think everything is normal and keep it from going into “limp mode”.
10– I recommend you install and “air tube” in the airbox to divert / dampen the air pulses the dead cylinder will create. These pulses mess up the A/F curve a bit.
11– tune it with a Power Commander or similar device
12– Please note: you may need to occasionally wipe oil residue out from the airbox.
*** You can use the stock header. So far we are getting the same power with stock and aftermarket systems.***
You can cut the disabled cylinder header pipe and cap it at both sides of the cut, or cap the exhaust side only and put a plate on the head at the exhaust port.
On a stock 2004/5 GSXR600, this will yeild about 70 RWHP and about 32/33 ft lb of torque on pump gas
Race fuels such as VP U4.4 will help it gain another 3 RHWP or so
Basically, we expect about a 30% loss of the unmodified 600 output.
The purpose of this tube is to minimize the air pulses from the dead cylinder into the airbox. They will make the A/F curve funky.
If you use a stock rubber velocity stack,
- use a piece of 1 1/4″ PVC tubing. add a short length into a 90 degree fitting
- then about 5-6″ into the other end of the 90.
- Add a cap onto the tube.
- Glue the short end into the rubber stack with some RTV
- I like to drill a 3/8″ hole in the cap to help balance pressures, but I don’t know that it matters
- point this at the font of the airbox between the ram air inlets
You can use a 45 fitting as pictured, but you don’t have to. If you don’t, the tube WILL hit the top of the airbox prematurely. This can be remedied by bending the tube by heating it with hot air, such as from a heat gun, Be careful! It’ll be pretty hot! Cool it with a wet rag once you’ve got it bent to where you want it.