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-   -   KLE500 rocker cover gasket. (http://www.horizonsunlimited.com/hubb/kawasaki/kle500-rocker-cover-gasket-45311)

g4wod_john 14 Sep 2009 22:03

KLE500 rocker cover gasket.
Quick question. I have to adjust my tappets and wonder if I need to purchase a new rocker cover gasket, or will the cover come off without damaging the old gasket.

Any thoughts

Cheers John

ShaunJ 15 Sep 2009 05:20

You can re-use the gasket just try not to damage it levering the cover off it can be quite tight, you will also need some silicon sealant which needs to be applied to the 4 lobes on the gasket which covers the end of the camshafts

g4wod_john 18 Sep 2009 22:06

Thanks for the information, you are right the gasket does come lose without damage, though one of the cooling system tubes wont budge the first one came out with a little bit of leverage but the second one will not budge, so I will have to wait until I can get a spare one just incase it gets damaged and I need to make a puller, who would think an oring seal could be so tight.

Cheers John

ShaunJ 19 Sep 2009 09:11

Can't rememeber exactly but isn't there a small lug welded onto them that a screw passes through

g4wod_john 19 Sep 2009 17:17

Yes you are correct there is a screw and I had removed it on both of the pipes, one of them is just stuck and the sort of force I was applying should have moved it.

Ah well it will keep to another day.

Thanks for the help.

Cheers John

ShaunJ 19 Sep 2009 19:08

Is it the right hand one thats stuck by any chance?

g4wod_john 19 Sep 2009 20:40

Yes it is the right hand one.


ShaunJ 20 Sep 2009 00:20

the right hand one on mine was rather tight think i levered it up abit on the lug using a flathead screwdriver then pulled it the rest of the way with needle nose pliers

drandy 29 Sep 2009 08:35

Last time I did this I had to totally mash my water pipes to get them out of the engine, spares were very hard to come across.

If anyone knows someone who is selling these new, please let me know as I am running on my old bashed ones siliconed into the engine!


ShaunJ 29 Sep 2009 15:30

try here i have no experience with them
OEM Motorparts - Kawasaki - KLE 500 - 2006

drandy 29 Sep 2009 15:45

OUCH!!! £26.80 each!!

nath23 7 Oct 2009 22:28

I just took mine out to do the valve clearances, it took a good 20 minutes or so of wiggling and good dose of wd40 to get them out - but they did eventually come out. I also levered with a flat head screwdriver. I'm told they are much easier to take out the second time. good luck.

johnquinnell 10 Oct 2009 12:03

If you are going to check your tappets, make sure you check your plastic coolant filer on the outside of your LH carbie. When I was doing my 24k service as per the manual, it was recommended that the plastic coolant filter be removed inspected/cleaned. I thought that was a bit of an overkill but did so just the same and was surprised at just how much crap was in it.

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