\"The Tingler\"

o.k. now to show my level of ignorance. I have 81 kz100m1 CSR. I have replaced rusted out oem pipes with 4 into 1 header and muffler. Jet kit installed, and individual breathing. My questions have to do with the exhaust return system. I have read that you can simply put plates in place of the reed valves. Then the whole Tingler can be chucked out. Well, if that's true, what about the vent in the transmission? Also, does removing this system remove the need for the vacuum hoses from carbs to fuel petcock? Because of some other unrelated issues this has been a two year project that I really want to finish. I have never ridden or even heard this bike with this equipment!

Switch, this is really a number of questions I will try and address...

"o.k. now to show my level of ignorance. I have 81 kz100m1 CSR. I have replaced rusted out oem pipes with 4 into 1 header and muffler. Jet kit installed, and individual breathing."

The Dynajet kit for this bike isn't really very helpful. You would be better served to replace the OEM jet needles and bump your pilot jets up one size from OEM and the main jets 3 sizes from OEM using genuine Mikuni jets. I am basing this on the use of a 4 into 1 and pods.

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"My questions have to do with the exhaust return system. I have read that you can simply put plates in place of the reed valves. Then the whole Tingler can be chucked out."

I suspect by TINGLER you mean the smog junk. I have never heard this term used before. First, remove the plates over the reed valves in the valve cover. Remove the reed valves and put plates over the openings or reuse the OEM plates and plug the holes or connect a hose between the two outlets. You can see pretty blockoff plates on the APE web site at:
www.kzzone.com/billet.html

You then work backwards and remove hoses and the cannister that is vacuum actuated. You will be pulling the vacuum hose from your carbs that goes to the cannister and putting a vacuum cap on it (3/16" cap).

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"Well, if that's true, what about the vent in the transmission?"

The transmisson and crankcase on your bike are shared and the vent is to vent the crankcase. I suggest you connect a hose to this vent and route it over your swingarm. Some folks like to put a filter on it so bugs won't climb in or something but since pressure is outwards, there isn't a problem I think. If you want a filter, go to an autoparts store and buy a fancy car crankcase filter which will slip right on the vent. I use a hose.

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"Also, does removing this system remove the need for the vacuum hoses from carbs to fuel petcock?"

Not only does engine vacuum actuate your smog devices but it actuates your petcock. If you remove that vacuum hose from your petcock it will no longer work in the ON position. If you remove the hose you will have to run in the PRIME position and will have no way of shutting gas off. If you do this, plug the port on the carbs as it will just be a big vacuum leak and the carbs won't run right.

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"Because of some other unrelated issues this has been a two year project that I really want to finish. I have never ridden or even heard this bike with this equipment!"

TWO YEARS? Go to local library and find a self-help book on overcoming procrastination! bwhahahaha

I'm not a kaw expert but I think you mean KZ1000? The smog system, if it's like what was on my 80 550 and my 95 1000, can be removed and the ports on the exhaust side valve covers can be plugged. I used rubber caps I bought at Autozone and the old clamps from old hoses. The smaller vacuum hose that goes to a T and then to two of your intake manifolds (front of carbs) can be removed and plugs added to cap off the vacuum ports on the intake manifolds. There should be a larger hose coming from the back of the smog vacuum switch that goes into your airbox. That can be removed and I used a larger rubber plug to fit tightly into that grommet in the airbox, closing off that hole. The smog vacuum device can be removed completely and I kept mine just in case they ever start checking for that stuff in my county on inspection.
The other vacuum line that goes from your carb manifold vacuum port to the vacuum port on the petcock is necessary to open the valve and let gas flow from your petcock in the On and Reserve settings. Most kz owners swap out the petcock with one that is on-off-reserve and not vacuum operated, and then plug that vacuum port on the carb.

Since you went with pods, and probably removed your airbox, or just aren't using it, someone else will have to chime in on the crank case breather vent part... I assume that's what you meant when you said somethng about the vent in the transmission...

Never heard the smog device called a Tingler...but I'm only a 4 month old KAW owner...

ADDED: And I type slower than WiredGeorge so ignore my post!:laugh:

Post edited by: fergyfer, at: 2005/12/30 09:58

Three sizes up on main jet? Really?

Pitch the smog junk, blank of any cam cover holes (plates can be bought or made). Crankcase vent dangle over chain for a drop of lube every now and then, or to a catch can if racing, even plumbed into exhaust to be blown out with rest of dead dinosaur remnants.

Yes you will need vac line to petcock.

On the air-suction-system, I replaced the valve cover plates with block-off plates, but I left the reed valves in place because they form a seal to the block-off plates. The reed valves are no longer needed, but I left them there for the seal.

The vent to the transmission is un-related to the air suction system. The trans vent is part of the crankcase vent system. Don't block it, just run a hose down as others have said.

I would also paint large pink numbers on your valve cover in the event you can't recall where the various cylinders are located! Bwhahahaha Sorry loudhvx... can't resist some times...

wiredgeorge wrote:

I would also paint large pink numbers on your valve cover in the event you can't recall where the various cylinders are located! Bwhahahaha Sorry loudhvx... can't resist some times...

Alright, but that's gonna make you fair game in the future

Post edited by: loudhvx, at: 2005/12/30 23:18

Thanks guys for the help. I think I am over my misgivings, and will carry on with this project. As for Procrastination, you have no idea what I have had to go through with the age and condition of the fasteners and some parts. ok, maybe you do. Being basically cheap has made it that much harder. HOWEVER, pink paint I can get, but I may think about a different service provider for my carbs! When she is running I will post a progress picture.