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Old 3 Jun 2009
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KLE500 Cold Starting Problem

For the past year, my '92 KLE has given me more fun than ever, problems as well !!

Every few months, it develops cold starting problem after overnight parking. It can fire up but cannot maintain idling, meaning die off immediately after throttle closed. I used to start without any throttle opening and it was Ok then. When bike is riden, it will start and idle perfectly.

When cold, and when it is able to idle, RPM is around 500 (guessing) and fully warmed up, it is around 1200-1300. If I mess around with idle setting screw, it will be ok for a while and need another messing maybe a week later.

It needs to go to my mechanic to readjust the valves, after which it will be perfect for a few months, then the same problem repeats.

Plugs replaced. Battery in perfect condition. Starter motor no cranking problem......

What could be wrong?
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Old 3 Jun 2009
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I expect that you are also using the choke when it's cold, so I'll continue from there.

If I were you, I would take a closer look at the carb, specially the jets (remember to look at the pilot jets; they are usually the ones that can cause problems!) and you could always take a look at the diaphrams, while you're at it!

When was the last time you did a carb sync?

How many miles/kilometers on the bike? When was the last time the carbs were checked (in miles/kilometers)?

I'm quite sure this is carb related...

edit: Missed a part. Does it run well after a valve adjustment, but will run bad only after a few months? That sounds strange. I would, however, take a look at the carbs, as it doesn't take that long, and can do wonders for the bike!
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Old 4 Jun 2009
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My KLE has clocked 63000km now. Most recent carb serviced about 6000km ago.

No. I do not pull the choke for cold start. That's because not only it doesn't help, it's even worse. Needed more cranks if choke is pulled.

Nothing else is meddled for a recovery. Just readjustment of valves. Not even the carb.

I am worry that the engine needs a complete tear down because the timing chain is also making noises. I am seeking advice to avoid that.....

BTW, I rode the bike "gently". Rarely exceed 7000rpm, casual speed 100-120kmh at 6th gear. Occasionnally runs continuously over 300km/day, mostly 80-90km/day to/fro work. No gravel road, 100% tarmac, single rider. Chain and rear sproket still original from new.

With above, I can rule out rider's fault !! Could it be engine life, by design? However, I'll look at the carb (pilot and diaphram...yes, copied that).

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Old 4 Jun 2009
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OK, just if your curious; the KLE engine is good, but it has A LOT of weak points, but to keep it simple: it will run for a long time, as long as it's been serviced as it should, and not driven to the red line most of the time, and kept "unmolested"

How many of those 63000KM have you been driving? It could be possible that the previous owners might have driven the KLE to the red line a lot, and that will eventually kill the engine.
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Old 5 Jun 2009
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I bought the KLE in 1997 with only 5000km clocked. Over the span of 13years, it was rarely used in the first 11 years. Only the past two years, it has done almost 40000km.

Again, I had a scared moment this morning....it can fire up but refused to idle.....forced to start in gear with cluth in for immediately taking off.... must do the valve adjustment again. This time round, perhaps I should reverse the sequence..... do the carb, test a while, then only valves adjustment and I will report back.
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Old 6 Jul 2009
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Forced to open up engine top due to leakage and eventually the whole engine block.

Found badly worn inlet valves. Their edges are sharper than razor..... What caused that?

This is the very first time this engine is being opened up and while waiting for replacement valve to arrive, I better find out the root cause and fix it.

Next question, should I also change the internal timing chain?

Thank you for helping.
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