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-   -   kle 500 exhaust (http://www.horizonsunlimited.com/hubb/kawasaki/kle-500-exhaust-41157)

nath23 27 Feb 2009 12:39

kle 500 exhaust
hi all, can anyone tell me if i would be ok to put a different muffler on a kle 500, one from another bike? what are the complications with this? i wanted to put a high performance one on and cant really afford to pay £350 for a new one, i was going to just buy a second hand muffler off ebay? any ideas anyone?

royzx7r 28 Feb 2009 11:18

I think there are a couple of people on here that have gone down that route.

You would have to cut off the end can on your standard system in order to fit a slip on end can. I guess it will make your bike run rich so you may have to re-jett and fit a better air filter.

If you check out some of the earlier threds, you may find the info you are after?.

Hope this helps?.


gray9893 1 Mar 2009 18:10

I've just done a very simple and effective mod, which has transformed the performance.

Any KTM SX or EXC silencer fits very well on the original pipe work (50mm bore - bearing in mind you have to saw off the old silencer). I bought an almost new one off ebay for £40. These are race exhausts but don't say not for road use, the SX is louder than the EXC which is more restricted. You will need to make a new bracket for the silencer to hang off (10 minute job). All you need to buy is a 50mm exhaust clamp.

I havent needed to rejet yet, but I will ounce I get my hacksaw out onto the airbox.

nath23 1 Mar 2009 20:12

many thanks
thanks you all. gonna go check ebay for a silencer.

nath23 1 Mar 2009 20:24

one more question?
sorry to be a pain, but does it matter what cc ktm the silencer is for? there are a few on ebay for the ktm 250 called powercore? they any good?

gray9893 3 Mar 2009 19:08

Hi matey,

The powercore will deffo fit as I had one on my race bike, but thay are very loud. I would try and get the standard exhaust, which is of course the part everyone replaces, which is why you can get them cheap, and they are made of top grade alloy, so weigh about 5kg less than the standard can. These are quiter than the aftermarket ones, which is plenty loud enough.

I'm fairly sure the all the standar 250 to the 525 are all a 50mm inlet bore, mines off a 2006 KTM 250f which works great, even the new black (2007-2009) ones will fit. I'll take some pics when I get my camera workin again. The very early ones 2000-2003 have a rounded flange so not sure about them.

Hope that helps, Gray

nath23 3 Mar 2009 20:42

thank you
your help is very much appreciated. there are loads on ebay, just wasn't sure if it had to be a similar size bike or a four stroke or what. will grab the next cheap one which comes along.
kind regards

gray9893 3 Mar 2009 21:00

3 Attachment(s)
Some pics to see how its done, deffo the four stroke. Cheap, but great improvement. Good luck


nath23 24 Mar 2009 00:39

one more question?
I managed to get hold of a ktm exhaust exactly the same as yours but would very much appreciate it if you could show me how you have attached yours? there is a little catch for a spring on the end can and am wondering how i can fix it onto the exhaust without using this? what did you do?
(oh, i have also bought a dna air filter and am gonne put some new spark plugs in it while i'm at it)
once again - your help is very much appreciated

gray9893 25 Mar 2009 21:18

Hi matey
All you need is to get a 50mm+ exhaust clamp, (any bike shop should have them) its like a giant jubalee clip, about 25mm wide, cut 4 slots in the end of the can and clamp it up. Thers's about 1mm of difference between the can and the original pipework, so you need to pinch it up. It doesn't have to be mega tight as the strength is in the bracket not the join. The springs don't fit anymore. You can just about see the clamp on one of the pics.
Release the power!! (well a bit)

Good luck

nath23 26 Mar 2009 23:12

exhaust clamp
hi again and thanks.
my friend thinks I'm mental cutting the end off a perfectly good, 2 year old, kawasaki exhaust, but hey, I'm gonna do it anyway. gonna get onto it soon and will let you know how it goes after. thanks for all your help.
kind regards

mrsibanda 2 May 2011 12:27

Hi Guys

I'm new here - so here goes for my first ever forum posting!! Firstly thanks for the excellent info on the ktm end can conversion. I've got a 98 KLE 500. I managed to get a 2010 KTM SXF end can really cheap on ebay. I chopped off the standard silencer this last weekend. I got the end flared and a spring mount welded on so that I could use a standard spring to hold it on. Used a bit of 3mm flat bar to mount the silencer using the the existing mount.

The bike sounds beautiful now (especially when lugged from 4k-5k rpm!) - well, the neighbours haven't complained yet! Maybe revs a bit more freely. I'm just waiting for jets and needles before I can fit the larger air intake snorkel (tried it out a couple weeks ago, but it made the bike hestiate really badly when accelerating at all from 1/4 to full throttle).

With just the end can it doesn't seem to need rejetting. On a 100 mile test run last night, I got just over 53 mpg, so no apparent change yet from having original silencer. Oh, by the way, I've got a K&N air filter fitted, and am running 17/46 gearing.

Thanks again, guys. Will let you know how the jetting comes on when I receive the parts.


mrsibanda 13 May 2011 15:19

1 Attachment(s)
Here's a picture if anyone's interested.

Jake 13 May 2011 17:06

Hi just cutting in on your thread here - any of you kle 500 guys want a freebie it will cost you the postage or you can collect its a centre stand and fittings for a 2005 kle b model. It wont fit the earlier bikes. Its free to anyone starting out and wanting one for there bike. These cost about £140.00 new so for the price of the postage - (i am not sure how much maybe £15.00 as it is quite heavy/Bulky to post) I will wrap it up and work out a postage cost if anyone wants it.


ps first to pm me will get it. cheers.

Paul.R 12 Jul 2011 21:46

Hi all,

I've recently done the same exhaust mod with the same ktm pipe, works a treat!

for those who want to know what the little kle sounds like with no pipe on imagine Thor gargling nails...or watch this vid.


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