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Photo by Sean Howman, The Pamir highway in an unseasonably cold late October, Tajikistan

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


Photo by Sean Howman,
The Pamir highway in an unseasonably
cold late October, Tajikistan



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  #31  
Old 9 May 2011
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non start kle500a1
well think i have got to the bottom of the problem . compressions . 50psi in one pot and 70psi in the other manual is saying it should be beetween 139psi and 213psi . but just 2 b sure i am going to recheck the valves clearances tonight . but i think its an engine out jop anyway . just need to sorce an engine or head barrels and pistons and valves i think
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  #32  
Old 9 May 2011
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Originally Posted by wildmetal View Post
well think i have got to the bottom of the problem . compressions . 50psi in one pot and 70psi in the other manual is saying it should be beetween 139psi and 213psi . but just 2 b sure i am going to recheck the valves clearances tonight . but i think its an engine out jop anyway . just need to sorce an engine or head barrels and pistons and valves i think
Put a few drops of engine oil in the pots then check again...

If the compression goes up, the problem is the rings/cylinder/head gasket

If it doesn't increase, its likely to be the valves.

Also, not wanting to patronise in any way but loads of people get compression readings wrong. They should be done with a WARM engine with the throttle WIDE open..

Also, if you have a £15 compression tester bought out of a magazine, bin it ! They're GROSSLY inaccurate, especially if they are the plug in type. You need a screw in !

The only way I can trust them is if I compare the readings with another bike that I know is healthy.

Ted
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  #33  
Old 13 May 2011
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non start kle500a1
ok i now know why theres no compression . one ring is broken and 2 others are stuck in the groove on the piston . i have never come across this before . must have been the carb cleaner that did it . the rings did have a fair bit of carbon inside the lip on the top edge so it was brob on its way out anyway . right so all i need now is pistons rings top and bottom gaskets and should be back on the road
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  #34  
Old 13 May 2011
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Originally Posted by wildmetal View Post
ok i now know why theres no compression . one ring is broken and 2 others are stuck in the groove on the piston . i have never come across this before . must have been the carb cleaner that did it . the rings did have a fair bit of carbon inside the lip on the top edge so it was brob on its way out anyway . right so all i need now is pistons rings top and bottom gaskets and should be back on the road
Yup... That will do it...

At least you know now.. You must of been going nuts !

Before you just throw it back together........ The bore is quite likely to be damaged if you've had broken rings..You're probably better off getting a second hand barrel off eBay or at least measuring it all up properly..

If nothing else, get the old barrel honed out and see if you need oversize rings..

Measure it all up properly,

Ted
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  #35  
Old 13 May 2011
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non start kle500a1
yep theres one good set on ebay for a gpz500 thats only done 17k hopefully this should b ok
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  #36  
Old 30 May 2011
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non start kle500a1 (update )
well it now gone bad . managed to get a gpz500 engine .engine was in and all wired up . wouldnt start . no oil pressure . batterys a bit low hoping its that . found out i needed to change the rotor from the kle500 to the gpz engine . this is were it went wrong . i busted one of the magnets on the rotor so i now have 2 engines that i cant use till i get a rotor . and it looks like there only one for the kle500. so if any one can help . i need to know what size puller i need to get the flywheel off . and would the rotor/pick up affect the oil pressure light (have changed the pressure switch for a good one )
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  #37  
Old 30 May 2011
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The cams are also different on the GPZ... Many people swap the cams anyway. gives it more uuuuumph !!
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  #38  
Old 31 May 2011
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non start kle500a1 (update)
yep i am keeping the cams from the gpz . i think the gearing not the same a the kle . so may have to go smaller on the front sprocket . its just the rotor that got me in a pickle now and the lack of oil pressure . i have now tryed a good pressure switch and its still showing no pressure . i am due to get some more barrels pistons and cams in the post next few days so i will hopefully at the end of all this have 2 good engines . but still stuck without the rotor
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