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Old 5 Oct 2009
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KLE 500 Airbox

Hi Guys,

Can anyone let me know how to fit a KLE500's air box. My bike did not come with one, but after some suspect lean-running, I decided I had better fit one.

I have removed the fuel tank and bracket, but am having trouble slipping it in behind the carbs, the rubber springy flanges do not want to play ball, what is the trick?


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Old 5 Oct 2009
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Just to let you know. The reason why your KLE 500 did not run well (I guess that's the situation, as you seem sure it's running lean (which is most likely the case)), is most likely due to a lean air-fuel-ratio, but that's not all. Carbs in general must retain the needed pressure difference between the venturi and the float for fuel to pass through the main jet, which is why a bigger main jet is usually needed when modifying the intake (though this applies to most carburetors), but the main difference is that the slide will have trouble rising without an airbox, which is why POD-filters (or not airbox at all) do not work well at all with CV-carbs.

OK, so how do you actually fit the airbox to the carburetors? There is not much space to play with, though this is usually not a problem.

I usually use a flat screwdriver to attach the ducts properly, connecting the airbox to the carbs (though be careful not to damage the ducts (rubber pieces)). Put a small amount of force to these rubber pieces away from the carbs, increasing the size between the ducts and the carbs, and then try to seat the airbox properly.

Make sure the springs are "slided away" while attaching the carbs to the airbox. When that is done, it's time to seat the springs in their correct position on the ducts.

There's not much more into it, as far as I can see (have never seen this as a problem at all, so might miss something).

If there's something else, please do not hesitate to ask. I might missunderstand the whole situation

edit: Quick question. Is the airbox from the same generation as your bike? Why I'm asking is due to the fact that KLEs pre 96 (96 included, if I am not incorrect), have a bigger snorkel than the newer ones. If you have a small snorkel on that airbox (see the carb tuning thread for picture references), the bike will not run well without modifications (if you have a KLE from 95).



Last edited by Mollrik; 5 Oct 2009 at 19:59.
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Old 6 Oct 2009
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Thanks for the advise, it was a total pain to fit!! I ended up loosening the carbs from the engine, fitting the box to the carbs, then fitting the whole thing back in. Finally got it in, then discovered that someone must have shortened the fuel pipe in the past, as that was a total nightmare to fit.

When I tried to start the bike, no electrical activity at all! Full battery, all connectors in place, all fuses connected.

I might have managed to damage the loom or something. Im stumped! I may have to dismantle it all and start again!

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