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KLE 500 Performance modifications needed. KLE 500 Performance modifications needed.
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  #1  
Old 12 Dec 2007
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KLE 500 Performance modifications needed.
Hi everyone. I am from Cape Town, South Africa and have just recently bought a new 2007 KLE 500. The bike is great. Best value for money, reliability and low running costs. I use the bike daily for commuting. Only one problem that I found is that the front break pads needed replacing after only 5800km!

I was wondering if anybody knew of any easy performance modifications that can be done to the bike, cause it seems the bike could do with a little bit more grunt. The motor is very willing and free reving. I suspect the problem lies with the exhaust. It looks a bit restrictive.:confused1: Any performance tips are welcome.

Cheers.
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  #2  
Old 12 Dec 2007
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Am yet to go down the performance enhancing route, but I believe the cat system on the kle is very restrictive. a "proper" exhaust would help considerably, but the carb jetting would require modifying too.
The cam profile on the kle is softer for a smoother low rev performance (alledgedly, my 2006 wouldn't pull the skin off an egg custard). gpz cams may sort that and take the power back upto the 50bhp mark.
I have no info on the ignition system.
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  #3  
Old 12 Dec 2007
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Thanx for the info. I'll probably start with the exhaust. Powerflow makes a nice system (stainless headers and silencer). Can get it here in SA. Do you have any info on the carb jetting requirements? I have asolutely no clue where to start. Also, what about the airbox/air filter?

Thanx.
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  #4  
Old 16 Dec 2007
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Quote:
Originally Posted by sparkie View Post
I have asolutely no clue where to start. Also, what about the airbox/air filter?
Try here Technologie & Ecologie : Motorbike - Kawasaki 500 KLE
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  #5  
Old 16 Dec 2007
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If using gpz cams, with a good inlet/exhaust, then the stock gpz carb jets will not be too far out. A bit of research (too late tonight for me) will give the jet sizes for the kle/gpz motors. take it from there.
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  #6  
Old 11 Jan 2008
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Go with the powerflow exhaust. Had a local guy here in PE (from powerflow) make me one from start to finnish. He did a good job and if those oaks do half as good a job you should still be happy. I also added a aftermarket airfilter and used a soldering iron to make some more holes in the air box. I then sent it in for a dyno. Boy what a difference.. I still have to come accross a 650 dual sport that will beat me from pull away to excelleration to top speed, alone or 2 up. Dont expect much increase on top end thou... You just get there a lot easier and hold it much better. Much better riding a 500c and leaving 650gs's or Klr's eating dust than riding a bigger bike and get eaten for breakfast by a 500cc.
ps. nothing was changed on the carbs except fine tuning it.
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  #7  
Old 11 Jan 2008
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Originally Posted by ronepaulsen View Post
.. I also added a aftermarket airfilter and used a soldering iron to make some more holes in the air box. I then sent it in for a dyno. Boy what a difference..
Can you tell me which aftermarket airfilter you use now.Tnx.
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  #8  
Old 12 Jan 2008
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[quote=ronepaulsen;167844]Go with the powerflow exhaust. Had a local guy here in PE (from powerflow) make me one from start to finnish. He did a good job and if those oaks do half as good a job you should still be happy. I also added a aftermarket airfilter and used a soldering iron to make some more holes in the air box. I then sent it in for a dyno. Boy what a difference.. I still have to come accross a 650 dual sport that will beat me from pull away to excelleration to top speed, alone or 2 up. Dont expect much increase on top end thou... You just get there a lot easier and hold it much better. Much better riding a 500c and leaving 650gs's or Klr's eating dust than riding a bigger bike and get eaten for breakfast by a 500cc.
ps. nothing was changed on the carbs except fine tuning it.[/quote

How much does the full system cost approx. and did you go for the free flow or street legal system? I cant find any pictures on the net of the Powerflow system. What make of air filter did you use and what type of minor tuning was doen to the carbs.
The info will be greatly appreciated.
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  #9  
Old 18 Jan 2008
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The air filter is DNA. K&N could not supply. Powerflow is a local exhaust manufacturing company ( mainly motor cars ) They do not mass produce pipes for bikes. Mine was a hand made once off deal for which i had to lay out R2500 ( compared to nearly R10 000 for the Arrow if imported) The carb settings was done by the chaps doing the Dyno. It is standard procedure of just setting the carbs to the optimum air/fuel ratios. nothing fancy like jet kits ect. I used a soldering iron to make the holes as not to get shavings from drilling into the carbs
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  #10  
Old 18 Jan 2008
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Quote:
Originally Posted by ronepaulsen View Post
I used a soldering iron to make the holes as not to get shavings from drilling into the carbs
Have you any photos of that? Tnx.
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  #11  
Old 31 Jan 2008
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Originally Posted by Nikola_M View Post
Have you any photos of that? Tnx.

Sorry just sold the bike in favour of the new BMW 800gs coming out in March. Never expected it to go so quickly. Had it advertised for one day and could already have sold it 3 times over. It is however very easy. Just remove the airfilter cover and air filter. Use a hot soldering iron to melt a couple of holes in the back of the housing opposite where the air filter sits. You will notice that the air intake is only the size of the top a match box. I made 6 holes, 5mm in diameter, to essensially double the intake capacity. basically in this shape :::
Last edited by ronepaulsen; 31 Jan 2008 at 20:01.
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  #12  
Old 9 Feb 2009
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can some one help me please KLE 500
Hello everyone i have a kle 500 guy i got it from said was running perfect some one hit it up the ass and it just wouldn't start again he said the bike is common for the timing going wen rear wheel locks up but i checked the timing and all seems ok i Thought maybe the carbs have gone so i sprayed some easy start in to the engine and it didn't attempt to fire so usually i would think spark plugs but why would they go from being hit up the ass it makes a tapping noise now and again when trying to turn it over and started motor seems to struggle a bit thats all i can say about it any help at all would be appreciated Thanks for Reading
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  #13  
Old 3 Mar 2009
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See exhaust mod thread

Gray
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  #14  
Old 8 Mar 2009
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can you not post a link to this thread of which you speak.
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  #15  
Old 15 Mar 2009
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exhaust mod
The link to the exhaust mod is
http://www.horizonsunlimited.com/hub...-exhaust-41157

I'm sure this will help more than messing about with your sprockets. The KLE already has a close ratio gearbox. If you decrease teeth on the front sprocket or add to the rear, your gear changes are going to be even closer together, ie you'll be in top gear by about 40mph and your top speed will be reduced.
Hope this helps
Gray
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