Stock airbox/ K&N setup /Crankcase breather setup

So what i am looking for is an answer to my dilemma. I Have a 1980 kz550 LTD and i would like to get it back on the road.
I removed the stock air box and replaced with K&N pod filters, capped the heads where the breather is at for the pcv and added a small filter on the bottom where the crank breather attaches to the stock air box. The bike is not running right and when it was running it was running super lean. What I am hoping to achieve is good gas mileage and quickness isnt really an issue. I did not change the jets in the carbs due to trying to get close to stock fuel mileage. What I am wondering is, should i just put the stock airbox and pcv setup back on? I know I was talking to a guy at work and he was saying that having the head breathers capped off is a big no no and could be most of the problem. what Are your thoughs?

For fuel mileage, the stock setup is really hard to beat. The hoses and reed valves on the cam cover is designed to introduce fresh air into the exhaust system to reduce pollutants, and has no effect on fuel mileage. If you want to remove that system, you will need to connect the two ports on the cam cover with a hose, or buy some block off plates.
Replacing the stock air box with pods makes the fuel mixture so lean that engine damage can occur. Larger jets are required to restore the proper ratio of air to fuel, and as you surmised, lower fuel mileage will result. To meet federal emissions regulations, Kawasaki set these engines up pretty lean frm the factory, so introducing more air without more fuel will cause the bike to run poorly at best.

P.S. search this discussion board for pod filters to see how difficult it can be to get the jetting right.

Yeah I basically removed the whole system already. Installed rubber caps with clamps on the tops of the heads where the hole is. Looks like deleting the stock airbox has caused more than one problem. Will capping of the holes in the top of the head cause excessive pressure in the heads?

No.. Though you may want to keep an eye on those caps to be sure they don't melt.

Definitely replace the stock airbox and filter. Ed

Put the air box back on. Pods are a PITA to tune and starve for air at high speed. There are ways to deal with that but you lose the "Cool" look. Make sure the intake boots are in good shape and not leaking.
The air injection system must be done away with correctly.
Some guys tear off items and wonder why the bike isn't working right. Best to stay as close to stock as possible. 4/1 header? Rejet. Pods? Rejet again. Look at the plugs. They will tell the story.
Steve

Don't listen to the anti pod guys, you can get them to work just as good as the stock airbox. If you have the stock exhaust do this. What style of carbs are on your bike, CV or slide? If CV then go up one size on the main jet and place a shim under the needles. If you have slide carbs, go up one size on the main jets and move the needle clip down one slot and up the pilot jet by one size. That should get you pretty close.
I have been running pod filters for a LONG time on a bunch of different bikes and I have gotten ALL of them to run correctly.
This bike has had pods on it for over 30 years and 150,000 miles, it runs perfect. Starts easily, pulls hard and smooth, no flat spots, is not effected by wind or rain and I have ran it from sea level to over 13,000 feet and it runs great. As for the caps on the valve cover, simply connect the two ports together with a hose.

This is what Baldy is talking about

I am not one of the anti-pod crowd. In fact, my main ride has a set on it. Pods look cool, sound cool and make getting the carbs on and off easier. On my ZRX, they also allow for the installationn of a very largr storage compartment.
What they will not do is increase fuel mileage, which the OP said was his main goal.

...I own bikes with and without pods. Yes, you can make them work. But, if milage is what you're looking for, the stock air box is the way to go.

...Pods will definitely give you a bit more performance, but slightly less gas milage. If you do stick with the pods, don't wait too long to jet those carbs. Unless, of course, you like Cobalt Blue head pipes. Along with other damage that is sure to follow.

When I bought my KZ, it had pods and stock exhaust (Kirker)I got amazing mpg. Almost 70mpg, verified by many of my friends. When I installed to V&H 4 into 1, I had to re-jet big time. I went down to around 35mpg. But it did have a whole bunch more power. The wind has only affected them if it is over 35mph and blowing completely into the side of my bike.