I was going to reply to your questions, but it suddenly dissapeared.
Your post now only says "Cheers" :thumbup1:
What chain and sprockets are you using?
Do you have a pannier rack? if so with which panniers? Have they survived everything you have thrown at them?
what do you know about engine rattles? There is alot of talk about the kle rattling but im going to have a look this weekend. Ever changed your camchain?
What about the front sprocket nut? is there a specific socket for it?
I will give you a bit of info tonight or tomorrow. A bit busy at work now and the internet connection at work is dead slow.
I am from South Africa and am mostly on a South African adventure riding forum called Wild Dog. Adventure riding has quite a big following over here. The perfect country for that type of riding. It's kind of a world in one country. See here: Wild Dog Adventure Riding - Index
I just changed my sprockets and chain last month. I went for genuine OEM. It's 17 front and 44 back. I didn't bother with aftermarket sprockets because the price differance was not that big. I went to my local tyre/exhaust shop and they used an inpact socket to get the front sprocket nut off as it was very tight.
I made my own luggage plate and pannier rack. I used it last year on a 4000 km round trip up to Namibia and it worked perfect.
Here's the link to the post on how I made it: KLE 500 D.I.Y. Soft Pannier Frames
Here is the link to the section that has KLE specific information: http://www.wilddog.za.net/forum/index.php?board=115.0
Engine rattles: My bike is a '07 model with 64 000 km on the clock. My tappets also rattle a bit on cold start-up. It's normal. Rather have loose tappets (not too loose) than tight ones. The bike still goes like stink!
You can download a parts manual here (it's for a '07, but most of the parts are the same): https://docs.google.com/open?id=0B5Z...thkey=CITBvpsN
Workshop manual here: https://docs.google.com/open?id=0B5Z...thkey=CITBvpsN
I've attached a few pictures of my recent Namibia trip.
Thanks heaps for your information.
So story so far, I still havent popped the valve cover. I bought a camera probe thing, inspection camera, new gasket for tensioner, top end gasket set...just incase. Compression is at 185psi ish in each cylinder so im not to worried. But I have had some bad luck with top ends so heres hoping. Just going to wait till everything arrives and go from there. Luckly i have a DR650SM waiting to in the wing. I can at least ride tarmac.
Still not sure on chain and sprockets...The stores charge almost twice as much as they are on the net but how do you know whats good? Ahhh just very frustrating. Is there any reason a front sprocket would wear fast? I have gone through 2 sets in just over 30000kms. I guess it could just be neglect on my part but i am pretty good with keeping the chain tensioned and lubed up. Does your front sprocket wear more than the rear?
I have been reading Wilddog for ages! Another great source. Adventure MX's post is freaken amazing. In fact i was just reading that Lecap says 9/10 its the tensioner. Or carb balance, Another thing i need to do. I dont know if it has ever been done. Seems every kawasaki dealer is dodgy as hell. But ill go on for hours if i get started. There seems to be heaps of KLE's in RSA, did they sell well over there? Are they generally used as commuters?
Im pretty restricted with space right now so whipping up a pannier rack at home is out of the question. but soon. I might see if the wolfman KLR 650 racks fit. Or adapt.
Thanks again for your help!
There are a few KLE's down in my neck of the woods. They weren't too popular and did not sell in great numbers over here. The KLR 650 is a more popular choice. Most KLE's like mine are used for commuting, although I have been on quite a few far-away trips on mine. The front sprocket does wear more than the rear. Keep your chain lubed and adjusted and it should last ok. Be careful of the KLE's top-end. They like to burn valves if the tappet clearances are not set correctly and checked at regular intervals.
I am using e-cheapo Oxford soft panniers at the moment. Worked quite adequite on a recent trip, however I am tempted to try out these new "Big Bag Panniers". I think they are similar to Giant Loop, but a lot cheaper. They are reasonably priced and sit on the bike well.
Big Bag Panniers, Soft Luggagge, Motorcycle Pannier bags, panniers
BTW, what country are you in?
Im in Australia, Melbourne. Ive only seen maybe 3 KLE's on the road ever. There certainly weren't any at Cameron's corner(where New south wales, Queensland and South Australia meet.). I would put some photos up but i cant seem to be able to work these forum photo things out. My KLE has served me so very well as an adventurer and city dweller. Freaken awesome bike. For the price.
I have been harassing quite a few people on various forums about a serious bash plate for the KLE. Do you know of anything?
Burn Valves...that sounds terrible. Do the specified intervals in the manual suffice? How often do you check?
I have been rocking the bags connection umm can remember what its called. should be called the "get burnt on exhaust when its full bag"...haha my fault really. the exhaust guard did a great job.
I dont mind the look of those bags. Its similar to what i have now but bigger. Is it just like a backpack and has one big compartment? Doesnt seem to have a price? I think im going to go with wolfman.
Damn still havent got that damn chain and sprockets...
Don't over tighten your chain or you will chew out the counter shaft bearing.
I'm not sure if my sprockets and chain are stock [at 47,000+km probably not], but whatever the numbers of teeth on each sprocket, I really like the combination for both road and trail.
Ock. [yes, it's me, from those other forums too :eek3: ]
Check the valves as per the spec in the manual (every 24 000 km), and you will be fine. I know someone who also has a KLE and he has 78 000 km on the clock and still going strong. I think the secret is that the KLE's engine is very understressed. The red line is 11 000 rpm and I do just under 6000 rpm at 120 km/h. The engine is not working that hard, so you will get good life out of it. :mchappy:
Just joined forum and loved the pictures. I have attached some pictures of the hard panniers I made for fishing trips with my son. Bought ammo boxes off Ebay and put two on the bike there and two on my other bike (hence different colours & bikes - still KLE's). Cost me 10 pounds a box and the rest was just aluminium poles etc, Very sturdy, holds loads of stuff and much, much cheaper than a Hepco Becker setup.
Hope you like them
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