Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Kawasaki Tech
KLE500 Rebuild KLE500 Rebuild
Register FAQ Calendar Today's Posts
Kawasaki Tech Kawasaki Tech Forum - For Questions specific and of interest to Kawasaki riders only.
Photo by Andy Miller, UK, Taking a rest, Jokulsarlon, Iceland

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


Photo by Andy Miller, UK,
Taking a rest,
Jokulsarlon, Iceland



Reply
Page 1 of 2 1 2
 
LinkBack Thread Tools Display Modes
  #1  
Old 8 Sep 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2008
Location: England
Posts: 152
KLE500 Rebuild
Decided to strip my KLE down and rebuild since winters have started to get the better of it.

Before







After powdercoat



Reply With Quote
  #2  
Old 9 Sep 2011
Registered Users
New on the HUBB
  
Join Date: Oct 2010
Posts: 11
Congrats for the beautiful frame color.
Reply With Quote
  #3  
Old 12 Sep 2011
Registered Users
HUBB regular
  
Join Date: May 2011
Posts: 65
I love these sort of threads, more pictures and descriptive please
Reply With Quote
  #4  
Old 12 Sep 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2008
Location: England
Posts: 152
Thanks for the comments.
Don't have much time at the minute so its going to be a bit slow hopefully be able to hit it hard after this weekend. So far few parts not shown have been cleaned and painted. And swingarm now has new bearings.
To do:
Clean and paint few more parts
Put in new headstock bearings
Rebuild brake calipers
Tidy up accessory wiring
Touch up paint on engine

Additions to be added at some point:
Braided front brake hose
Uprated rear shock
Uprated fork springs
Stainless respoke on front wheel
Reply With Quote
  #5  
Old 13 Sep 2011
Registered Users
New on the HUBB
  
Join Date: Aug 2011
Posts: 10
That looks fantastic!
I've been thinking about stripping mine down and doing the same. Any top tips for things to look out for ?
Reply With Quote
  #6  
Old 18 Sep 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2008
Location: England
Posts: 152


Progress front and rear suspension done. Although thinking that i might take the forks out again and spray them to match the swingarm, the silver just seems too bright by comparison.


Top tips:
Make sure to attach the swingarm rubber before fitting the swingarm.
Take note of the orientaion of the rear shock when removing. I put mine back in and found the swingarm was hitting the spring, rotated it 180deg about its axis and it bolted right up.
Reply With Quote
  #7  
Old 22 Oct 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2008
Location: England
Posts: 152
Made some more progress on Thursday







Reply With Quote
  #8  
Old 22 Oct 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2011
Location: Slovenia
Posts: 105
Nice coloro of the frame, like it very much, keep the pictures comming
But I have spoted that you have allready mounted the SW-Motech crash bars, I hope you know that with the bars mounted you can not mount on the side fairings. You will have to remove the bars to be able to mount the fairing.

Thumbs up for your poject though
__________________
->Honda XL125V Varadero '08 sold
->Kawasaki KLE 500 '05 riding it, like I stole it
Reply With Quote
  #9  
Old 23 Oct 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2008
Location: England
Posts: 152
Quote:
Originally Posted by Ghosty_SLO View Post
Nice coloro of the frame, like it very much, keep the pictures comming
But I have spoted that you have allready mounted the SW-Motech crash bars, I hope you know that with the bars mounted you can not mount on the side fairings. You will have to remove the bars to be able to mount the fairing.

Thumbs up for your poject though
Thanks
The bars were only on loose in those pics hence no cross brace just wanted to get a feel for what it will look like


Some more progress from the weekend









And some teaser shots


Reply With Quote
  #10  
Old 26 Oct 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2011
Location: Slovenia
Posts: 105
That red frame fits really nice with the gray fairing, now only crash bars need to be red. Nice project, keep the pictures comming
__________________
->Honda XL125V Varadero '08 sold
->Kawasaki KLE 500 '05 riding it, like I stole it
Reply With Quote
  #11  
Old 26 Oct 2011
Contributing Member
Veteran HUBBer
  
Join Date: Jun 2008
Location: Seville (E)
Posts: 561
Beautiful!
Nice red frame! I admire these jobs, so much knowledge and effort behid. Amazing what you've done.

Esteban

PS: Your new white handelbars look great, I should get one of those. My parrot would enjoy the trips much more than inside the panniers.
Reply With Quote
  #12  
Old 13 Nov 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2008
Location: England
Posts: 152
Bit of a late update
Heres last couple of weeks progress





Reply With Quote
  #13  
Old 16 Nov 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2011
Location: Slovenia
Posts: 105
It looks like more like a KLE after each post That frame loks very nice with gray fairing. But I have a question for you. Do you have a complete arrow exhaust or just endcan? Can you take some pictures of how the pipes are layed out if you have a full sistem.

Thanks
__________________
->Honda XL125V Varadero '08 sold
->Kawasaki KLE 500 '05 riding it, like I stole it
Reply With Quote
  #14  
Old 16 Nov 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2008
Location: England
Posts: 152
Its a full system the pipes follow the same route as normal although you lose about 1 inch of ground clearance where the left pipe curves around the back of the sump
Reply With Quote
  #15  
Old 19 Nov 2011
Registered Users
Veteran HUBBer
  
Join Date: Sep 2011
Location: Slovenia
Posts: 105
Quote:
Originally Posted by ShaunJ View Post
Its a full system the pipes follow the same route as normal although you lose about 1 inch of ground clearance where the left pipe curves around the back of the sump
Thanks for the info, I am looking for a new exhaust pipes, the stock ones are quite heavy.
__________________
->Honda XL125V Varadero '08 sold
->Kawasaki KLE 500 '05 riding it, like I stole it
Reply With Quote
Reply
Page 1 of 2 1 2

« Previous Thread | Next Thread »

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
Top End rebuild Lamin Sambou Yamaha Tech 9 3 Jun 2009 18:30
34L fork rebuild andylarkin Yamaha Tech 5 23 Jan 2009 17:22
BMW R80 Carb Rebuild gsworkshop BMW Tech 2 11 Jun 2007 08:40
Top end rebuild bolla Yamaha Tech 3 15 May 2006 21:28
Top End Rebuild Geoff van de Merwe Yamaha Tech 4 23 Dec 2002 04:11

 
 

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. 11-14
  • 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!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

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 05:56.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top