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?

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?.

Roy:thumbup1:

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.

many thanks
 

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

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?

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

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
Nathan.

Some pics to see how its done, deffo the four stroke. Cheap, but great improvement. Good luck

Gray

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

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

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
Nathan.

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.

Cheers.

Picture
 

Here's a picture if anyone's interested.

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.

Jake.

ps first to pm me will get it. cheers.

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.

http://i1126.photobucket.com/albums/..._VIDEO0004.jpg

Changed my can as well...
 

Mainly so I could fit the panniers in nice and tight. I used my KLE for commuting (lots of filtering) and the only real problem was not being able to fit the centre stand with this exhaust. The can is right-hand side from an XJR1200, nos cheap on ebay.
Cheers, Richard.

hey wobbly,

Nice silencer - great idea for fitting the panniers. What's it sound like?

I ended up mounting a bracket to keep my soft panniers from touching my silencer.

I've been struggling to find replacement headers and have just seen these on eBay - handy for when my headers succumb to rust!

http://www.ebay.co.uk/itm/1406202388...84.m1423.l2649

Cheers, Rory

Hi Roy
 

It sounded like a normal jap bike bike, too damn quiet!
The pipes from sandybikespares look good. I've used their downpipes on my 600 fazer and an 600 diversion at work with no probs. The only issue would be if you to use a centre stand, best check before you buy any.

Cheers, Richard.

Hi Guys

Here's a sketch of the how I attached the KTM silencer. It might help anyone who's keen to do the mod.

Cheers, Rory

Ive just ordered one of these
Lextek Slip-on Exhaust Silencer Race Can Kawasaki Z 1000 Z1000 03-06 Motorcycle | eBay


looks to be about the right length and diameter with a 51mm inlet so hopefully it will fit straight on, bit nervy in cutting the old system though lol

Ill post up some piccies once done see what you guys think

Hey. It would be nice to see pics of how it ended. Unfortunally I don't have garage, I will have to wait for cca 2 months, to get my KLE from my place to welder..Too cold for a drive :) but thanks to mrsibanda, I have a clear idea what to do :) I will post some pictures too.

here we go

http://i225.photobucket.com/albums/d...ps75f62ee9.jpg

And the sound? :) Could you upload a video? Looks great!! :)

OMG thats by far to technical for me to do unless someone can tell me how its done !!!

But it does sound nice lol :funmeteryes:

Cant beleive with the arsenal of bikes ive now got this little thing has inspired me and ive just finished addressing some of the points that others say are an issue and have
Replaced
Renthal enduro High bars
16t front sprocket (now Back to STD 17)
Decent Handguards
DNA air filter
End Can
Pazzo short levers
Fat Foot Pegs
EBC sintered HH pads
Braided brake hoses
Pirelli MT21s
Heated Grips
30mm raised dog bones
forks dropped in yolkes
Givi Trekka 46ltr
12v Acc Socket
Removet the crappy bit under reat mudguard
Smaller no plate
raised front mudguard 1.5 Inch (Not pictured below)

Triumph tiger 800 hasnt been touched since I bought this
My turbo Hayabusa has only done 31 miles since the last MOT 8 Months ago
BMW 1150GS ADVSE still in plastic bubble done 16 miles since i bought it !!
Suzuki RV125 Still needs a refurb
1600 Marauder 50 miles since full restoration (Now for sale )

Complete exhaust system
 

Hi there all,

I had a complete exhaust system fitted to my 2007 model. It ran better straight off ie:without re-jetting. Already had a better airfilter fitted - unifilter brand. Got about an extra 20 - 25 KM from full tank to reserve.

Cost was $ 700 AUD, but that got rid of the cats and uneven headers. Lost about 15 mm in clearance and probably means I cannot fit centre stand.

Then added athe larger snorkel with the front airbox cover modified as per the german instruction, to open the airbox up. At the same time had the main jets changed to 115's (or maybe 118's ??).

This changed the whole effect. Revs free from idle to redline (not done often) without the loss of power above about 8500 RPM as previously experienced. Also used to labour below 3000 RPM, now this effect is at about 2200 RPM. Fuel consumption did not alter from the increase after the exhaust change.

I don't expect it to be a race machine (not bought for that purpose), but it has inreased the percieved power and is easier to handle at slower speeds and in traffic etc. Another benefit is the exhaust note is louder than stock, so now cagers can actually hear me when alongside them, that way they have an idea there is something nearby them and (most times) have a look before moving accross lanes.

Regards,

Shaun

My KLE all done waiting to go out for a decent ride

http://i225.photobucket.com/albums/d...pse9775e87.jpg

Could you share what Headers and some photos of it? The mileage improvement seems great!

KLE500 exhaust
 

Hi there Austinmation,

photo's of exhaust are not possible at the moment. I crashed it about two weeks ago and it is currently with my mechanic awaiting insurance assessment.

I am also away from the district at present and will not be back until 19/20 Mar. Will take photo's after then, if the insurance hasn't written it off and taken it away by then.

Regards,

Shaun

Exhaust system
 

Hey again all,

cannot get photo's of the aftermarket exhaust system at this time. The insurance company have written it off and are sending it to a an auction house, without allowing me to buy the wreck beforehand.

The rear frame was bent and as such became an immediate write off.

Word of warning - had over $2900.00 of accessories fitted (not including some of the fittment costs), had informed the insurance company. Now with a claim in, I am informed the value insured did not increase to cover the accessories. Value they will give is the market value and to them it includes everything on it.

Thus out of pocket once again.

Check your insurance value and the coverage they provide.

Expensive lesson learned.

Fun riding everyone.

Shaun

Shaun,

Yes - expensive lesson learned. Try this one out though; demand your accessories back - if their claim that the accessories have not "increased" the value of the bike to them, then they should have no problems returning the accessories to you in return for the standard items previously removed. Check the fine print of your policy with respect to accessories fitted/notified and their ownership once a claim is lodged.

ALWAYS remove accessories that are not covered by insurance BEFORE the assessor has a chance to look at your insured pride and joy. They are YOUR property and if they are uninsured, then the insurance company has NO CLAIM on them.

Cheers
Ian

Hi,

can you tell me which EXCEL rim you used ?

Exhaust modification
 

Hi, just wondering, to all you guys who have changed from the stock exhaust, whats the improvement like?
Im considering changing the exhaust on my 06 KLE as the original is looking a bit rough and the improvement would be nice!
I was looking a a full stainless system on ebay for £300, which looked good, any thoughts? would I need to get the jets changed?
Also I would like to keep the good fuel economy, or ideally improve it for touring would you think this is realistic?
Any people in the uk have any idea what a garage would charge to change the jets and tune it?
looooads of questions I know but im a bit new to this! :blushing:
Cheers all!

Hi Rockmonkey,
I've just changed the silencer - but will have to do the exhaust when it finally rusts through! I don't think that you'll need to do the jetting if you change the exhaust - the bike will run fine. However, I've just seen this old airbox on ebay with the larger intake snorkel, which is a straight swap to the newer KLE's:

KAWASAKI KLE500 AIR BOX FROM 1993 BIKE | eBay

If you get hold of one of these, you'll need bigger jets and needles. My bike (with old style large snorkel) goes well with 112 main jets and N96J needles, and sounds good with a ktm silencer. The jets etc are available from Corby Kawasaki (very good service).

Hope this helps. Cheers, Rory

cheers for that!
 

thanks for that Rory, thats what i was hoping to hear, to be honest I dont want to change my bike too much as I like her as she is, just a bit more ooomph would always be nice though! I'm taking her to morocco with my mate on his transalp 700va and i dont want to be lagging too far behind when i'm all loaded up!
Matt

Hi Matt, You shouldn't have any trouble keeping up with a transalp - just requires a few more revs. My bike holds up fine with daily 80-90mph dual carriageway stints (about 45mpg). Enjoy your trip!

Hey all.

As i promised I'm posting some pictures of my new exhaust. I tried one from KTM, SP brand, but it was little too loud for me while riding for more than 2 hours..but sound...well that was somthing else :funmeteryes:

This video was taken just to test the sound. Taken with camera on the phone...It sounds lot more bassier than on the video bier

Test izpuha - YouTube

Curently have this on:
http://shrani.si/t/3i/WS/4IZVDPsq/motor.jpg
Not the same, but still A LOT better than stock. Changed stock filter with DNA filter and the exhaust..the bike feels better..like totaly different KLE :thumbup1:


Still got that other exhaust (from the video) if anybody is interested :)

Just fixed my exhaust today:
KLE 500 Exhaust change - YouTube

I have just fitted my KLE with the KTM exhaust but not as yet tried it out. It sounds good ( for a parallel twin which will never sound great) not too loud but a more chesty sound.
My plans are to re-jet the carbs, probably 112's/118's and also to slightly open up the air box. All standard stuff. I like this bike but I'm used to more power tho this will take me in comfort any where I want.
Ultimately I want an '08 GS1200 again. I once had a '04 GS 120-0 but sold it, wish I hadn't.
For the time being I'll keep the KLE, I'm enjoying all the improvements I'm doing. I'll also look at the front suspension as I want it just a little better than standard even with the great improvement I made by pumping 4 strokes with a bicycle pump. Maybe slightly stronger springs.

S.C.