Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Kawasaki Tech
Kawasaki Tech Kawasaki Tech Forum - For Questions specific and of interest to Kawasaki riders only.
Photo by Alessio Corradini, on the Salar de Uyuni, Bolivia, of two locals

I haven't been everywhere...
but it's on my list!


Photo by Alessio Corradini,
on the Salar de Uyuni, Bolivia,
of two locals



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 21 Aug 2013
Registered Users
New on the HUBB
 
Join Date: Aug 2013
Location: Devon, UK
Posts: 18
High Rev Issue KLE500 '93

Firstly...Hello!

As usual, i am one of those who have been loitering in the background awaiting my confirmation email so i can get stuck in with asking questions and generally enjoying one's self which brings me onto my first question issue/question relating to my bike.

It is a 20 year old Kwack KLE500...i purchased it with this problem ( reflected in the price i might add ) and was keen to get my hands dirty sorting this, and a few other, issues out.

In a nutshell, over 6-7k revs in any gear it will run as intended for about 20 seconds, then will pop, buck, fart, lose speed, throttle response and all manner of PITA running...if i ease back on the throttle it'll calm down slightly but if i was to pull over she'll just happily die on me for 5 minutes before starting back up again...if however i continue to ride along at a lower rev then she will still backfire/pop/fart etc until i stop and she conks out ( see the waiting 5 minute rule ).

Now then, i do know abit about bikes ( how many have said that !! ) and from her behaviour i would say it's a cylinder not firing at the point she goes all wobbly on me, but is this a carb related issue or electrical?

I stripped the Carbs last night, gave them a clean although they were looking in pretty good shape ( one did have traces of rust in the float bowl, very minor and an old issue by the looks of it ) and installed back on today, i checked the coils and got 3.2ohm and 18k ohm on both and checked and maintained the air box was correctly fitted.

So any ideas my fellow KLE owners? Most point to the carbs but I'm chin scratching as to why it happens at high revs AFTER 20-30 seconds and not straight away...
Reply With Quote
  #2  
Old 21 Aug 2013
Registered Users
Veteran HUBBer
 
Join Date: Sep 2011
Location: Slovenia
Posts: 105
Hey!

Welcome to the forum. I really can't help you with the specific problem, but I can supply you the service manual if you wan't to dig deeper in to the problem.

Cheers!
__________________
->Honda XL125V Varadero '08 sold
->Kawasaki KLE 500 '05 riding it, like I stole it
Reply With Quote
  #3  
Old 21 Aug 2013
Registered Users
New on the HUBB
 
Join Date: Aug 2013
Location: Devon, UK
Posts: 18
Quote:
Originally Posted by Ghosty_SLO View Post
Hey!

Welcome to the forum. I really can't help you with the specific problem, but I can supply you the service manual if you wan't to dig deeper in to the problem.

Cheers!
Hey Ghosty

That would be a great help!
Reply With Quote
  #4  
Old 22 Aug 2013
Registered Users
HUBB regular
 
Join Date: Jun 2008
Location: NSW, Australia
Posts: 62
Lift the tank, make sure none of the hoses under the tank are pinched, route them so that they do not pinch when you put the tank back on; enjoy....

Cheers
Ian
Reply With Quote
  #5  
Old 26 Aug 2013
Registered Users
New on the HUBB
 
Join Date: Aug 2013
Location: Devon, UK
Posts: 18
Quote:
Originally Posted by Jameseye View Post
Lift the tank, make sure none of the hoses under the tank are pinched, route them so that they do not pinch when you put the tank back on; enjoy....

Cheers
Ian
The tank has been off and on so many times over the last week and each time the breather pipes are routed cleanly away, i wish it was such a simple remedy!

To date i have now done:

Valve clearances
Cleaned carbs, full strip down, checked jets were clear
New air filter
New plugs
Checked coils


I've also attempted to balance the carbs...i say attempted but the results were quite good but not perfect. Using a Souriau 2440 Indiana i was getting 1085 mbar on carb 1 @2k revs but a fluctuation of 1045-1062 mbar on carb 2 and no matter how i adjusted the pilot screw, it continued to fluctuate.


I don't hold much faith in the airbox tbh, the seals between it and the carbs are quite frankly, crap. I'd rather be looking at individual K&N style air filters for each carb and needle/jet set up as well, this is something to ponder.

The fuel tank isn't in great shape, the fuel tank cap area is rusted, i assume from years of being outside and a bad seal around this area...saying this the fuel in the float chambers has always been clean, no signs of contamination as such ( old rust spots from an issue some time ago, i imagine she was stood for some time ) but on a run yesterday i opened up the filler cap to make sure the tank could breathe and eliminate that thought.

So fueling wise i'm nearly 100% happy with the results...other than the 2nd carb not playing ball, the difference at 2k revs is minimal and i can live with it ( the bike is beautiful to ride up until the issue kicks in @7k revs ) so where do i go from here?

Replace the fuel tank as it's an easier option than repairing.

Electrical issue...coils are the first thought but why only at high revs?

to be continued.....
Reply With Quote
  #6  
Old 28 Aug 2013
Registered Users
HUBB regular
 
Join Date: Oct 2011
Posts: 50
That is a real good one...Could be something to do with your timing. I would check compression too. Im not sure if the looming is the same but I have had a few electrical issues myself. Mostly due to corrosion and dirty connections. Get some contact cleaner, unplug, spray, plug, unplug, plug. Might need some cotton buds for some terminals. If your in Melbourne, Aust. I have a compression tester and timing light I could lend you.

Best of luck!
Reply With Quote
  #7  
Old 29 Aug 2013
Registered Users
New on the HUBB
 
Join Date: Aug 2013
Location: Devon, UK
Posts: 18
Quote:
Originally Posted by leonator View Post
That is a real good one...Could be something to do with your timing. I would check compression too. Im not sure if the looming is the same but I have had a few electrical issues myself. Mostly due to corrosion and dirty connections. Get some contact cleaner, unplug, spray, plug, unplug, plug. Might need some cotton buds for some terminals. If your in Melbourne, Aust. I have a compression tester and timing light I could lend you.

Best of luck!
I'm looking at electrical issue atm...i'm going through the whole shebang and checking all the connections...as well as riding her daily with no issues below 7k revs..she's a real fun ride!

I'd love to take you up on the offer of the compression test but i'm UK based so it would be a fairly long ride...but tbh i reckon the ol girl would make it!
Reply With Quote
  #8  
Old 2 Sep 2013
Registered Users
HUBB regular
 
Join Date: Oct 2011
Posts: 50
There is no question. She'd love a ride like that! Have you had any break-throughs?
Reply With Quote
  #9  
Old 4 Sep 2013
Registered Users
New on the HUBB
 
Join Date: Aug 2013
Location: Devon, UK
Posts: 18
Indeed she would

I've done a 200 mile trip today and not an issue with her a all...over 8k revs in top gear for nearly 20 minutes and not even a hedgehog sized hiccup from the engine...

I did 'open' up the exhaust slightly to allow her to breath outwards more and she is better overall although still abit sluggish in the low range still but I'm looking for a replacement tank as it needs some tlc especially around the filler cap area...
Reply With Quote
  #10  
Old 25 Sep 2013
Registered Users
Veteran HUBBer
 
Join Date: May 2013
Location: Wisconsin, USA
Posts: 827
My guess is something to do with the pulse generator or cdi., mostly the cdi. They have a tendency to do goofy thing when they get hot, then cool down and work good for a bit. As for running , even though crappy, till you idle it down then puking it definitely sound s cdi issue. Most of these cdi have 2 advances, one at 8-12BTDC for starting(low rpm) and then switch to 28-39BTDC(depends on brand/model/year). As they fail sometimes one advance quits and it'll run, somewhat, on the other. In this case it sounds like the start advance(low rpm)has quit and the normal one is failing as it heats up.
Try tapping on the cdi when it acts up to see if anything changes.
My other guess is the pulse gen not sending all signals when it gets hot.
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Risers or high bend bars? MadM Kawasaki Tech 16 20 Mar 2013 18:33
KLE500 A3 Front sprocket issue... Orlow Kawasaki Tech 2 14 Aug 2012 22:44
kle500 starter clutch issue, info please: Joe C90 Kawasaki Tech 0 2 Mar 2012 20:37
rev counter wacky thang! derekd BMW Tech 2 23 Nov 2011 01:13

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now
, and add your information if we didn't find you.

Next HU Eventscalendar

ALL Dates subject to change.

2025 Confirmed Events:

  • Virginia: April 24-27 2025
  • Queensland is back! May 2-4 2025
  • Germany Summer: May 29-June 1 2025
  • CanWest: July 10-13 2025
  • Switzerland: Date TBC
  • Ecuador: Date TBC
  • Romania: Date TBC
  • Austria: Sept. 11-15
  • California: September 18-21
  • France: September 19-21 2025
  • Germany Autumn: Oct 30-Nov 2 2025

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.




All times are GMT +1. The time now is 10:20.