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  #1  
Old 29 Jan 2009
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KLE 500 Aftermarket Exhaust/DNA Filter combo thoughts?

Hi there.

I was wondering if there was anyone out there that has a 2005+ KLE 500 with the cat exhaust system and changed the canister part of the exhaust only with a slip on aftermarket one and put in a DNA air filter.
I am considering the option.
What performance improvement did you get? Is there quite a noticable differance in power? Lastly is it realy nessisary to re-jet the carbs or is it ok to leave it as is.

Cheers
SPYE
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  #2  
Old 30 Jan 2009
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Check this link: http://www.horizonsunlimited.com/hub...038#post176014
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Old 31 Jan 2009
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I installed the DNA air filter today, still with the stock pipe. Oh boy, what a differance even with the stock pipe on. It pulls a bit better and definately revs much quicker. Next step is to change the exhaust.

Cheers
SPYE
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  #4  
Old 8 Feb 2009
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staintube exhaust?

hi.
this all sounds very interesting. i just bought a kle 500 a few months back and i love it but would love it to go a bit faster too. where can i get a staintube exhaust from and a dna filter? how much do they cost and would i need to do anything else?
any input is very much appreciated.
kind regards.
Nathan.
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  #5  
Old 12 Feb 2009
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I would highly recommend a DNA air filter and aftermarket exhaust. You will get at least an extra 5HP and will be much quicker off the mark. Will run rings around most 650 singles.
Type in "DNA air filters" in google. I'm not sure of a supplier in the UK. Arrow make a nice full system for the KLE 500. It's a bit pricy here in South Africa so I had a local guy make up a slip-on tail piece for me.

Cheers
SPYE
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  #6  
Old 5 May 2009
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Hi,
I'm reading your e mail this morning. Just bought my KLE and concider doing the same by fitting a DNA air filter. Could you perhaps shed more light on the jetting of the carbs.
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  #7  
Old 5 May 2009
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Quote:
Originally Posted by Natal Shark View Post
Hi,
I'm reading your e mail this morning. Just bought my KLE and concider doing the same by fitting a DNA air filter. Could you perhaps shed more light on the jetting of the carbs.
Hi there.

The 05~08 KLE 500 main jets are different sizes, namely #95 and #92 for the left and right carb respectively. Kawasaki have larger jet options for these carbs. I would start off with some mild jetting and see how it goes. I have ordered some jets for mine and am still waiting.

Start off with installing #100 and #98 for the left and right carb, also install one 3mm spacer washer under each jet needle. This should improve things quite a bit as with having a free flowing zorst and DNA filter you will definately need to do some jetting as the bike is probably running a bit on the lean side. Alternatively if you have some cash then you can dyno-tune the bike with the profesionals. You can also read my other thread here: http://www.horizonsunlimited.com/hub...ing-carb-41935

The Kawasaki OEM part numbers for the jets are as follows:

Jet-Main #100 - 92063-1006
Jet-Main #98 - 92063-1005

Cheers.

BTW. I have a spare parts manual for the 06~07 KLE 500 if you're interested. Can email it.

Last edited by SPYE; 5 May 2009 at 18:58. Reason: Edit 1
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