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(making a) Symmetrical exhaust system for KLE500 (making a) Symmetrical exhaust system for KLE500
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Photo by Alessio Corradini, on the Salar de Uyuni, Bolivia, of two locals

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



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  #1  
Old 29 Mar 2015
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(making a) Symmetrical exhaust system for KLE500
I recently acquired a 1991 KLE500 with about 40k on the clock, and I've been scouring the web for information about the bike and how to improve its performance.
Ive found allot about the airbox etc, but it being a 1991 model it already has the larger snorkel.
Another thing that kept popping up was "problem with exhaust pipe dissymmetry". I read up some more about that and it seems a symmetrical exhaust system improves just about everything about the engine handeling.

Now I wonder, has anyone tried modifying an ER5, GPZ500 or EX500 exhaust system to fit a KLE and see if it improves performance?

I tried searching the forum and the web, but I can't find anything about somebody making a more symmetrical exhaust system for the KLE. Is it just not worth it?

The reason for my reasoning is that they seem symmetrical and are made for almost the exact same engine, I thought this would be a better start than to build one from scratch.

On another note, does anyone know how much the end-can/muffler weighs? before I saw it off in an effort to shed some weight, Id like to know how much I would loose.
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  #2  
Old 29 Mar 2015
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Quote:
Originally Posted by londen View Post
I recently acquired a 1991 KLE500 with about 40k on the clock, and I've been scouring the web for information about the bike and how to improve its performance.
Ive found allot about the airbox etc, but it being a 1991 model it already has the larger snorkel.
Another thing that kept popping up was "problem with exhaust pipe dissymmetry". I read up some more about that and it seems a symmetrical exhaust system improves just about everything about the engine handeling.

Now I wonder, has anyone tried modifying an ER5, GPZ500 or EX500 exhaust system to fit a KLE and see if it improves performance? No I have not tried

I tried searching the forum and the web, but I can't find anything about somebody making a more symmetrical exhaust system for the KLE. Is it just not worth it? There is a guy in Germany making them, from the TWIN500 forum, but at the moment I cant find the thread. Will post a link, if I manage to find it.

The reason for my reasoning is that they seem symmetrical and are made for almost the exact same engine, I thought this would be a better start than to build one from scratch.

On another note, does anyone know how much the end-can/muffler weighs? before I saw it off in an effort to shed some weight, Id like to know how much I would loose.
I h ave used a Z750 end-can on my KLE, before I sold it. Also some people have used a KTM 4-stroke end-can with successes.

FOUND IT: http://twin500.net/index.php?page=Thread&threadID=6296 It is a 24 page thread, and you need to register at the site to see it. When I was looking at getting a set, the price was 245€+shipping.
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  #3  
Old 30 Mar 2015
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Thanks MadM! this is exactly what Im looking for. Great inspiration, now all I need to do is brush up on my German :P
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  #4  
Old 27 Apr 2015
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Here is a solution that I found that someone had done. You do however have to move the oil pressure switch. It apparently greatly improves performance. See pictures to get an idea.
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(making a) Symmetrical exhaust system for KLE500-vcomqpg5szkn.jpg  

(making a) Symmetrical exhaust system for KLE500-z22dbnyb0mas.jpg  

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  #5  
Old 1 May 2015
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Thats some great looking diy-ing!

Another thing that might work, I've read, is the stock exhaust from a ER-5, except the bash plate won't fit with it.

I'm still on the fence, and on a tight budget, but once I get my welder fixed Ill do some baking.
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Old 2 May 2015
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Originally Posted by londen View Post
Thats some great looking diy-ing!

Another thing that might work, I've read, is the stock exhaust from a ER-5, except the bash plate won't fit with it.

I'm still on the fence, and on a tight budget, but once I get my welder fixed Ill do some baking.
ER-5 Exhaust will fit, but you will lose hight on already low ground clearance (180mm) and as you said, the bash plate wont fit.
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