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20 Jan 2009
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Join Date: Feb 2008
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A few KLE mods
Greetings to everyone from Finland.
I bought the bike last spring and ended up modifying it a bit:
First of all the engine was replaced with a gpz unit since the transmission broke from the original one (flywheel...). During the summer I modified the airbox http://kuva1.kuvablogi.com/iso/img1130747.jpg and retuned the carbs. Then the winter came.
The suspension is pretty crappy and wilbers shocks cost a lot... So I took the measurements of the old shock and started looking for a replacement. I found a possible candidate from a Honda XR600R. Only problem was, that the piggy bag reservoir hit the rear swingarm. So I took the shock apart and sawed the reservoir off.
http://kuva1.kuvablogi.com/iso/img1592649.jpg The date is wrong.
http://kuva1.kuvablogi.com/iso/img1592652.jpg And the date is still off.
I fitted a hose in between the two parts and got it serviced.
http://kuva1.kuvablogi.com/iso/img1690474.jpg
And in it went. It's a tight fit, but it works.
http://kuva1.kuvablogi.com/iso/img1690475.jpg
The reservoir went in behind the battery. With a little heat I molded the rear fender to accept the reservoir.
The front I equipped with progressive Wilbers springs. I also made 4 mm shorter dog bones to the rear. A little more ground clearance and a bit steeper front sounds good to me.
http://kuva1.kuvablogi.com/iso/img1690476.jpg
The KLE with the front end off. Notice my pneumatically operated bike stand.
http://kuva1.kuvablogi.com/iso/img1690477.jpg
As everyone knows, the exhaust system isn't that good... Very unequal length primaries with a a weird collector. I looked up the laser exhaust and it was almost as bad. At least they had fixed the collector, but the pipes were still way off.
So I made my own idea of a decent exhaust. I got the end can from a Hayabusa, it's a Yoshimura RS-3. I built the exhaust so, that it's still possible to use the original belly pan. It's not ready yet, and it still needs a little work to get it the way I want it.
A few more pictures of the thing:
http://kuva1.kuvablogi.com/iso/img1690481.jpg
http://kuva1.kuvablogi.com/iso/img1690485.jpg
Silencer flange: http://kuva1.kuvablogi.com/iso/img1690484.jpg
http://kuva1.kuvablogi.com/iso/img1690480.jpg
After the snow melts and I get the carbs retuned I'm thinking of getting the bike dynoed. I'm wondering whether to open the engine or not. I might modify the the head a bit and raise compression, but I'm not sure if I have the time since I don't wan't miss any riding time
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20 Jan 2009
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Join Date: Nov 2007
Location: Ireland
Posts: 111
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nice lookin bike, kle great bike and i like what you did with the exhaust. old one is not best and prone to damage.
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I spent 90% of my money on women and drink. The rest I wasted
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21 Jan 2009
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Nice one! Good lookin pipe
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21 Jan 2009
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21 Jan 2009
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Join Date: Nov 2007
Location: Ireland
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i am jealous of thoes pics, wouldnt mind having some where like that close buy to go out on a bike
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I spent 90% of my money on women and drink. The rest I wasted
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22 Jan 2009
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Join Date: Apr 2008
Posts: 46
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Found these which may be of intrest to you
ex 500, gpz 500, gpx 500, factory pro, carburetor, shift, ignition, prodk05.html, products ex500, gpz500, 97-99
Tuning 500 KLE
Kawasaki EX 500 Twin (87-92) Performance profile to increase
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20 May 2012
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Join Date: Feb 2008
Location: argentina
Posts: 3
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Hi to all kle fans
Y am from Argentina and own a kle 500 92 travel once a year with a friend who also has a kle.We have done some modifications on the bikes,Y will post some soon.
Good journies.
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24 May 2012
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Join Date: Apr 2012
Location: kent
Posts: 11
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bike looks good can i have a few more pics of the panniers+rack please and are they pellican cases if so what size?
cheers
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17 Jul 2012
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Join Date: Sep 2011
Location: Slovenia
Posts: 105
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Does anyone have pics from his mods? Links don't work :-S
Thanks!
__________________
->Honda XL125V Varadero '08 sold
->Kawasaki KLE 500 '05 riding it, like I stole it
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