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KLE500 Rebuild KLE500 Rebuild
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  #1  
Old 8 Sep 2011
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KLE500 Rebuild
Decided to strip my KLE down and rebuild since winters have started to get the better of it.

Before







After powdercoat



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  #2  
Old 9 Sep 2011
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Congrats for the beautiful frame color.
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  #3  
Old 12 Sep 2011
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I love these sort of threads, more pictures and descriptive please
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  #4  
Old 12 Sep 2011
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Thanks for the comments.
Don't have much time at the minute so its going to be a bit slow hopefully be able to hit it hard after this weekend. So far few parts not shown have been cleaned and painted. And swingarm now has new bearings.
To do:
Clean and paint few more parts
Put in new headstock bearings
Rebuild brake calipers
Tidy up accessory wiring
Touch up paint on engine

Additions to be added at some point:
Braided front brake hose
Uprated rear shock
Uprated fork springs
Stainless respoke on front wheel
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  #5  
Old 13 Sep 2011
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That looks fantastic!
I've been thinking about stripping mine down and doing the same. Any top tips for things to look out for ?
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  #6  
Old 18 Sep 2011
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Progress front and rear suspension done. Although thinking that i might take the forks out again and spray them to match the swingarm, the silver just seems too bright by comparison.


Top tips:
Make sure to attach the swingarm rubber before fitting the swingarm.
Take note of the orientaion of the rear shock when removing. I put mine back in and found the swingarm was hitting the spring, rotated it 180deg about its axis and it bolted right up.
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  #7  
Old 22 Oct 2011
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Made some more progress on Thursday







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  #8  
Old 22 Oct 2011
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Nice coloro of the frame, like it very much, keep the pictures comming
But I have spoted that you have allready mounted the SW-Motech crash bars, I hope you know that with the bars mounted you can not mount on the side fairings. You will have to remove the bars to be able to mount the fairing.

Thumbs up for your poject though
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->Kawasaki KLE 500 '05 riding it, like I stole it
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  #9  
Old 23 Oct 2011
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Quote:
Originally Posted by Ghosty_SLO View Post
Nice coloro of the frame, like it very much, keep the pictures comming
But I have spoted that you have allready mounted the SW-Motech crash bars, I hope you know that with the bars mounted you can not mount on the side fairings. You will have to remove the bars to be able to mount the fairing.

Thumbs up for your poject though
Thanks
The bars were only on loose in those pics hence no cross brace just wanted to get a feel for what it will look like


Some more progress from the weekend









And some teaser shots


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  #10  
Old 26 Oct 2011
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That red frame fits really nice with the gray fairing, now only crash bars need to be red. Nice project, keep the pictures comming
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  #11  
Old 26 Oct 2011
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Beautiful!
Nice red frame! I admire these jobs, so much knowledge and effort behid. Amazing what you've done.

Esteban

PS: Your new white handelbars look great, I should get one of those. My parrot would enjoy the trips much more than inside the panniers.
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  #12  
Old 13 Nov 2011
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Bit of a late update
Heres last couple of weeks progress





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  #13  
Old 16 Nov 2011
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It looks like more like a KLE after each post That frame loks very nice with gray fairing. But I have a question for you. Do you have a complete arrow exhaust or just endcan? Can you take some pictures of how the pipes are layed out if you have a full sistem.

Thanks
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  #14  
Old 16 Nov 2011
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Its a full system the pipes follow the same route as normal although you lose about 1 inch of ground clearance where the left pipe curves around the back of the sump
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  #15  
Old 19 Nov 2011
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Quote:
Originally Posted by ShaunJ View Post
Its a full system the pipes follow the same route as normal although you lose about 1 inch of ground clearance where the left pipe curves around the back of the sump
Thanks for the info, I am looking for a new exhaust pipes, the stock ones are quite heavy.
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