Well Having a lot of bike repair experience from scooters right up to superbikes the KLE 500 has been awful simply because of the carbs!

Got a 2005 model with a aftermarket end can inc pipes. and it would not go properly.

SO- Fitted new carb components and it still would not start or run.
DID- Ultrasonic clean on them and still it was not getting fuel. could only conclude the internal channels were blocked on the mix etc so binned the carbs.
GOT- new carbs and fitted all the new parts, I never re jetted kept stock air filter and small snorkel inlet on box. and it ran fine only to then again start causing issues.

THEN- the dam thing flooded fuel all over the floor. stripped again to find fuel tip has dirt from tank stopping it cutting the fuel in the float chamber. sorted that

NEXT- it would not go above 60 mph with out stuttering and sputtering. SO had to re do the float levels to 18mm book says (17mm +2m) that sorted that, as it was not getting enough fuel.

ONLY - to then have it flood again and had to strip it and clean.

Rough riding under 5000 revs so put in a DNA filter ran better then at low revs it started to cough and splutter so removed and popped in stock filter again, and put in two new ignition coils just incase.

The bike must have the air box in place to run correctly and I have kept it in place, but seriously the fuel tank tap pipes are really very inaccessible and give little scope to fit in an in fuel line filter. let alone connect it all back up.

I was ready to sell the bike and be done with it, The air box design is awful its so tight to fit in and connect the carb mouths to it let alone the two underside breather pipes.

That aside its such a great ride and I do like it but I ask this...
Is there any other carbs I can fit to avoid the on going issues I seem to have? these CK carbs are so sensitive and cause endless problems.


The carbs have been all stripped and fully rebuilt inc all top diaphragm parts learned a lot about the bike and its been interesting. But ideally looking to see if a different carb set up can be used to allow me to do away with the air box totally.


Thanks any input welcome.

Something is not right, or missing or worn out.

I would start again with the old carbs that were on the bike when you got it.

Set everything back to standard as much as possible.

Get it running, then tell us what the bike is doing or not doing.

I found the issue. Thanks for the input.
I had not physically removed the fuel mix screws as these were still sealed. Thinking these were ok and being sealed did not want to upset the factory settings.
I removed the sealed covering plugs and put in new fuel mix needles and seals. turned out to 1 3/4 turns.

This appears to have sorted it and it revs and rides just fine. no hesitation or lack of power. and I also noticed that less smell from the exhaust where before it was very much smelling of fuel.