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kerker too loud 10 May 2024 08:41 #898834

  • Fox
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Hello, i actually have an old kerker 4in1 on a kz1000 ltd with kz900 ltd carbs stock. Engine is stock.
The sound is too loud so i have to work on it.
It's the competiion baffle from kerker.
What can i do on the baffle? open it an Add new glass wool ... or steel wool ...
Replace it for the street mac baffle or and other one ...
What can i do on the carbs? Lean them ?

Thanks to help me before cops did it :)
1978 KZ1000-B2 LTD
1977 kz1000-B1 LTD

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kerker too loud 10 May 2024 08:55 #898836

  • Nessism
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I think there were three levels of baffles: comp, regular, and quiet.  Didn't the quiet baffle come on the Kawasaki branded Kerker's?  I've seen photos of these baffles, and they didn't seem overly difficult to try to replicate.  Easy for me to say, though...
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kerker too loud 10 May 2024 09:03 #898838

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I have the original kerker end cap if that can help on something...
1978 KZ1000-B2 LTD
1977 kz1000-B1 LTD

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kerker too loud 10 May 2024 09:49 #898840

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What if anything have you tried to decrease the level of "loudness" from your exhaust system?  Have you pulled the current baffle just to see what is there?  I do not have any practical experience with the Kerker/baffle(s) but on my exhaust it has a baffle that is little more that a pipe that is almost as long as the "megaphone" with lots of holes drilled on it, that connects to an end cap. I have made use of several different types of sound deadening material over the years. Fiberglass that would be used in building (walls ceilings etc) water pipe heating wraps and even an asbestos mat that was purchased for guitar repair. It by far lasted the longest, but it too required replacement after it too became too loud. I will not say I tend to replace whatever is currently being used each and every riding season, but would say it certainly happened more frequently than other regular maintenance items. (brake pads/shoes, cable lubes and adjustments ect.

I would encourage you to take a look at what you have and what you could try to lessen the sound level with it before I went looking for another solution. But what do I know?
 
1977 KZ650 B1
Pods and Denco header


This is my Z

OLD KAW OWNERS SMILE ALOT
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kerker too loud 10 May 2024 10:26 #898841

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Hello,

yes i will check. Here we can have a clear picture of how it the baffle normally. With aluminium foil... I will do it.
1978 KZ1000-B2 LTD
1977 kz1000-B1 LTD
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kerker too loud 10 May 2024 10:46 #898842

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Take a look at Howard's "ELR Tribute" project thread, he has recently refurbished a  Kerker pipe
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kerker too loud 10 May 2024 11:45 #898845

  • Injected
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Hello,

yes i will check. Here we can have a clear picture of how it the baffle normally. With aluminium foil... I will do it.
 
What is the purpose of the tin foil??

I use wire to hold wrap on. You can buy brand name baffle wrap online all over the place. I used "DRC" brand wrap recently, used by motocross guys.

 
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kerker too loud 10 May 2024 11:56 #898847

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Just don't wrap the wadding "too tight" if it's compacted it won't "baffle" if you choose to make a new baffle "custom chrome" sell perforated tube (it's £15 per meter in the UK so I guess will be comparable where you are (Howard was out of luck as there isn't a distributor in South Africa so he had to drill a gazillion holes  )
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kerker too loud 10 May 2024 19:12 #898871

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As far as I know the baffle with the aluminum foil is the race baffle. The Kawasaki by Kerker baffle was the reaaaaaally long one. I can take a pic of mine if ya need
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kerker too loud 11 May 2024 19:07 #898905

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The competition baffle is only about 8" long and a larger size pipe for the exhaust, where the street version is longer by far with a smaller pipe for exhaust. I can't say exactly, but probably 18" long more or less. They are both wrapped in fiberglass or whatever that eventually burns off. 
321,000 miles on KZ's that I can remember. Not going to see any more.
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kerker too loud 11 May 2024 21:08 #898908

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Correct on the longer, quieter baffle.  Those were the ones sold by Kawasaki as an aftermarket in house item.  They normally did not require any change from stock jetting. But you did need to adjust the idle circuit a bit.  Yes, the pictured one appears to be a shorter "race" baffle. With the foil wrapped too tight, it does nothing to baffle the exhaust pulses.  Really ends up being a straight through pipe without baffling.  As others suggested, baffling material is available from various sources.  Fill the void between the outer pipe and the baffle tube.  Completely wrap from the cone tip to the baffle plate inside the megaphone.  Not too tightly, but not too loose either (its an acquired skill.....)  And you will need to re-pack at a later date.. 
On jetting, when we would mount Kerkers on the stock 77 KZ1000s with race baffle, I recall going up 2 sizes on the main, may be 1 on the low speed, and raising the needle by one notch.  Typically ran a bit richer than stock, with appropriately lower fuel mileage.  BUT!  Hole shots were something else!  Take a plug reading after trying this.  You might end up going back down 1 size on the main.  Todays fuel concoctions are a quite bit different than they were in 1977.
EKKAWI
1976 KZ400D
1977 KZ1000A1
1976 KH400
1979 XS400
1980 KZ550A
1980 KZ750E
1983 GPZ550
1979 KZ1000B LTD
1986 ZG1000 Concours
1982 XS650 Turbo
KZ1000C
KZ1000P
1978 KZ650C (×2)
2003 BMW R1150RT
2014 BMW R1200RT (Current ride)
1971 Norton 750 Commando
1979 KZ1000A3A MKII (Present project)
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