Lamp One Designs - PAIR Removal Kit - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 73 (permalink) Old 12-30-2011, 12:12 AM Thread Starter
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Lamp One Designs - PAIR Removal Kit

I bought one of these kits about three weeks ago. Tonight I finally had some time in the garage to install it. First off, it's a very nicely done kit. I went ahead and bought the optional blockoff gaskets for an extra $5.00. The kits cost $26.00 including shipping. The kit is offered up for sale in Classifieds\For Sale section.
https://www.ex-500.com/index.php/topi...msg525439.html


Here is the kit as I received it. There is a well written paper with installation instruction included. The installation instructions are also available as a download on the seller's site.




The plates are pretty thick, as are the Kawasaki blockoff gaskets.





First the tank must be removed. I always take off the front fairing when I do this because I usually don't have a helper and this prevents me from scratching up the fairing while removing the tank. After I removed the tank and front fairing everything is very easy to get too. If I hadn't stopped to take pictures the removal of the PAIR system and installation of this kit would have taken just a few minutes.

Here is a top view of the engine with the PAIR system still installed.




The block off plates go on the left and right sides of the valve cover. Before they can be installed, the PAIR tubes must be removed along with the reed valves. Since I bought the optional PAIR blockoff gaskets, I didn't have to reuse the reed valves as gaskets. If you don't buy the blockoff gaskets the reed needs to be removed from each valve to keep the reed retaining screws from holding up the blockoff plate and keeping them from sealing properly.




Before the blockoff plates can be installed the PAIR tubes need to be removed. An 8mm socket and racket is your friend here. A universal joint is helpful for the left side if you have one as it's a bit more crowded on that side.




The PAIR tube has been removed, exposing the reed valves.




Removal of the right side valve assembly. I used an inexpensive pry bar that I had. (Purchased at Harbor Freight.)




Blockoff plate being installed.




Left carb nipple and cap.






Carb cap installed.




The large tube that enters the air box just pulls out. It is a pretty snug fit so don't be afraid to muscle it out. For this kit, the rubber grommet for that large tube has to be removed as well.

The air box blanking grommet before installation. (Left side shot.)




Air box blanking grommet installed. (Right side shot.)




The PAIR system has been removed. This is much cleaner and the bike is a bit quieter as well as the PAIR system adds some intake noise. The the noise difference isn't great.




The complete PAIR system.








Edit: Fixed typos

Wife's bike - 2005 Ninja 500<br />My bikes - 1998 VFR800, 2002 CBR954RR
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post #2 of 73 (permalink) Old 12-30-2011, 2:18 AM
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Re: Lamp One Designs - PAIR Removal Kit

Great write-up, thank you!
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post #3 of 73 (permalink) Old 12-30-2011, 10:46 AM
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Re: Lamp One Designs - PAIR Removal Kit

I vote this thread for a sticky.

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post #4 of 73 (permalink) Old 12-30-2011, 12:03 PM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by toddlamp
Great write-up, thank you!
Wow, you came through with this product fast! Good for you, Todd.
post #5 of 73 (permalink) Old 12-30-2011, 12:40 PM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by 00ninja
I vote this thread for a sticky.
+1




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post #6 of 73 (permalink) Old 12-30-2011, 1:14 PM
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Re: Lamp One Designs - PAIR Removal Kit

Though this is more of a HOW TO... isn't it.


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post #7 of 73 (permalink) Old 12-30-2011, 1:33 PM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by Rinzler
Though this is more of a HOW TO... isn't it.
Sure. Could it not be a sticky in the "How-To's / FYI" section?

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post #8 of 73 (permalink) Old 12-30-2011, 1:37 PM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by stormcat
Quote:
Originally Posted by toddlamp
Great write-up, thank you!
Wow, you came through with this product fast! Good for you, Todd.
Not as fast as I wanted to. Couldn't have done it without your help!
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post #9 of 73 (permalink) Old 12-30-2011, 2:25 PM Thread Starter
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Re: Lamp One Designs - PAIR Removal Kit

Thanks for all the positive comments.

The procedure is really easy. I decided to take some pictures and do a quick write up to show some of the less experienced members that it really is not difficult.

Heck, the EX500 is pretty easy to work on, especially when you know how to do it. These forums have been very helpful to me in that regard.

Wife's bike - 2005 Ninja 500<br />My bikes - 1998 VFR800, 2002 CBR954RR
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post #10 of 73 (permalink) Old 12-30-2011, 2:27 PM
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Re: Lamp One Designs - PAIR Removal Kit

Thanks for giving back, both to toddlamp and ex500husband.


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post #11 of 73 (permalink) Old 12-30-2011, 3:14 PM
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Re: Lamp One Designs - PAIR Removal Kit

^^ Well said!

And thanks to you as well Rinzler for making it a sticky.

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post #12 of 73 (permalink) Old 12-30-2011, 4:51 PM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by Rinzler
Thanks for giving back, both to toddlamp and ex500husband.
Thanks. I do what I can.
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post #13 of 73 (permalink) Old 12-30-2011, 5:33 PM
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Re: Lamp One Designs - PAIR Removal Kit

Is there thread where we can vote for the best post of 2011?
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post #14 of 73 (permalink) Old 12-30-2011, 5:38 PM
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Re: Lamp One Designs - PAIR Removal Kit

i'm pretty certain you wouldn't want to rummage through 92,482 posts to pick a winner.


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post #15 of 73 (permalink) Old 1-27-2012, 8:21 PM
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Re: Lamp One Designs - PAIR Removal Kit

I just installed this kit on my bike.
The kit is very professional, I'm very satisfied.


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post #16 of 73 (permalink) Old 2-28-2012, 10:27 AM
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Re: Lamp One Designs - PAIR Removal Kit

What is the advantage to doing this? I ride mine everyday so i dont want any long term side effects to show up
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post #17 of 73 (permalink) Old 2-28-2012, 10:30 AM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by scottsdale
What is the advantage to doing this? I ride mine everyday so i dont want any long term side effects to show up
This is basically done for 2 reasons:
- To prevent future problems with the pair system, since it doesn't contribute anything to the functionality of the bike, it's just easier to go on the safe side and remove it.
- To get rid of the clutter - you'll gain easier access to the carbs, plugs and the valves cover

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post #18 of 73 (permalink) Old 2-29-2012, 11:32 AM
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Re: Lamp One Designs - PAIR Removal Kit

Something I haven't seen noted with this.

My EX-500 is a California bike, so it has extra crap hooked into the pair system (Ie a big black box thing that is secured to the tank bracket).

So how different is the procedure with w CA bike, versus how simple it is for non-California bikes?
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post #19 of 73 (permalink) Old 2-29-2012, 12:02 PM
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Re: Lamp One Designs - PAIR Removal Kit

Just remove the canister, cap the vacuum lines, cap the return line at the front of the tank, and route a breather hose from the other one. Or cap them both and install a 48 state filler cap.


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post #20 of 73 (permalink) Old 2-29-2012, 12:21 PM
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Re: Lamp One Designs - PAIR Removal Kit

Thanks Rinzler, I plan on removing all that crap in the next few days after I have my bike emissions tested either today or tomorrow.
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post #21 of 73 (permalink) Old 2-29-2012, 12:43 PM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by Rheiga
Something I haven't seen noted with this.

My EX-500 is a California bike, so it has extra crap hooked into the pair system (Ie a big black box thing that is secured to the tank bracket).

So how different is the procedure with w CA bike, versus how simple it is for non-California bikes?
I had asked about the CA models before putting out the kit to see if removing the PAIR kit affects the California emissions and was told that it does not. Is that not the case? Does removing the PAIR system on California models leave open ended connections? If so please let me know so I can look into what parts would be needed to make sure the CA owners get complete kits.
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post #22 of 73 (permalink) Old 2-29-2012, 5:53 PM
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Re: Lamp One Designs - PAIR Removal Kit

Thanks Alon look like I knnow what im ordering this weekend But just out of curiosity, wht DOES (or supposed to) the PAIR system do?
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post #23 of 73 (permalink) Old 3-3-2012, 6:04 PM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by toddlamp
Quote:
Originally Posted by Rheiga
Something I haven't seen noted with this.

My EX-500 is a California bike, so it has extra crap hooked into the pair system (Ie a big black box thing that is secured to the tank bracket).

So how different is the procedure with w CA bike, versus how simple it is for non-California bikes?
I had asked about the CA models before putting out the kit to see if removing the PAIR kit affects the California emissions and was told that it does not. Is that not the case? Does removing the PAIR system on California models leave open ended connections? If so please let me know so I can look into what parts would be needed to make sure the CA owners get complete kits.
The Pair system only has one connection to the extra California Emmisions components. It is a single vacuum line that connects with a t-fitting to the right side Carb vacuum line.
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post #24 of 73 (permalink) Old 3-3-2012, 10:55 PM
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Re: Lamp One Designs - PAIR Removal Kit

What hapens if you dont remove the reed valves?




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post #25 of 73 (permalink) Old 3-4-2012, 1:24 AM
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Re: Lamp One Designs - PAIR Removal Kit

Quote:
Originally Posted by Rheiga
Quote:
Originally Posted by toddlamp
Quote:
Originally Posted by Rheiga
Something I haven't seen noted with this.

My EX-500 is a California bike, so it has extra crap hooked into the pair system (Ie a big black box thing that is secured to the tank bracket).

So how different is the procedure with w CA bike, versus how simple it is for non-California bikes?
I had asked about the CA models before putting out the kit to see if removing the PAIR kit affects the California emissions and was told that it does not. Is that not the case? Does removing the PAIR system on California models leave open ended connections? If so please let me know so I can look into what parts would be needed to make sure the CA owners get complete kits.
The Pair system only has one connection to the extra California Emmisions components. It is a single vacuum line that connects with a t-fitting to the right side Carb vacuum line.
Thanks. So it sounds like installing my kit,as it is sold now, on a CA model would leave an open hole on the T-fitting? When revoving the PAIR setup could you also remove the T-fitting and run the line directly to the carb nipple that is capped on non-CA models? Any chance you could send me pictures? I really don't like selling a kit to someone only to have them realize halfway through that they need another part. So the way it sounds now is that they will either need another vacuum cap or not need one at all since the CA emissions components would still use the carb nipple that the PAIR system uses. Thanks for the help.
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