Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Kawasaki

Kawasaki Kawasaki Tech Forum - For Questions specific and of interest to Kawasaki riders only. Questions comparing which bike is best etc go in the "Which Bike" forum.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 20 Feb 2011
Registered Users
HUBB regular
 
Join Date: Apr 2008
Location: uk
Posts: 37
non start kle500a1 part 2

well i still have a problem starting the kle . its getting a spark and fuel . i have checked the timing and that seems fine .the valves were a little tight these are now ok . i did however find that the ignition pick up was out of spec . so that was replaced . still a no go . could this be compression ? are there common broblems with kle,s . as was running fine before i used carb cleaner
Reply With Quote
  #2  
Old 25 Feb 2011
Registered Users
New on the HUBB
 
Join Date: Jan 2011
Location: tyneside
Posts: 17
double check the carbs

seems like you've either put em together wrong or dislodged/loosened some crap that's still there
used to have an import zzr400 that that ran poor despite using 3 cans of off the shelf carb cleaner got em ultrasonic cleaned and the bike was perfect

also check you haven't trapped a fuel/breather hose or a wire when putting the carbs back on
more info would be good as well...are the plugs wet or dry after trying to start and what did you do re the pickup coil?
Reply With Quote
  #3  
Old 27 Feb 2011
Registered Users
HUBB regular
 
Join Date: Apr 2008
Location: uk
Posts: 37
non start kle

plugs are wet . had the carbs apart 3 times now all seems fine . but will check again tommorow. as for the pick up. i replaced that with one in spec .
Reply With Quote
  #4  
Old 4 Mar 2011
Registered Users
New on the HUBB
 
Join Date: Jan 2011
Location: tyneside
Posts: 17
if the plugs are wet it's either not sparking,sparking at the wrong time or it's getting too much fuel.

put new plugs in, make sure the choke is not sticking, the air filter is clean, recheck the float heights and double check the gap between the pick up coil and the rotor

did once have a bike that ran like a bag o shite everything else checked out ok but noticed the tag holding the pick up coil had been bent...closed the gap up to about 1mm and all was good

just trying to eliminate things as you said it was running fine before.

its an A1 yep?...if so are you sure it hasn't had an engine change to a 500s motor?...i seem to recall the pickups were different from the kle...might just be the grey matter breaking down tho
Reply With Quote
  #5  
Old 6 Mar 2011
Registered Users
HUBB regular
 
Join Date: Apr 2008
Location: uk
Posts: 37
non start kle500a1

yep its an a1 500cc . checked the carbs again last night . all look ok float levels etc . i didnt think the pick up coil was adjustable on these as theres no adjustment on the 2 bolts , air filter all clean . new fuel and new plugs . i am rearly stumped on this one . i have worked on my own bikes ( fzr zxr rdlc xl dt ) for 20+ years and never come across somthing like this . i may even try to get a second hand engine to try . as i need to get this back on the road asap
Reply With Quote
  #6  
Old 7 Mar 2011
Registered Users
Veteran HUBBer
 
Join Date: Jul 2008
Location: Aussie expat in Switzerland half way RTW
Posts: 613
Ok, I'm no mechanic and I'm jumping into the middle of the thread I know but I feel that I'm missing half the story. It seems like you have thoroughly checked the carbs and spark plugs but starting from the begining, if you will, what else have you done (failing that was there a previous thread that you explained all this and I've just missed it ).

As with the usual 'bike doesn't start' issues, dunno if it will help but...

Check the following:
1. Battery has juice
2. Starter turns over
3. Spark plug actually sparks (pull it out but still connected, put it next to a piece of metal - turn over the bike and look for the spark)
4. Fuel - not flooded or dry - ensure no air bubbles in fuel line
5. Air - air flow/intake is clear

Failing that very basic checklist that I'm sure you've already done. What did you do to the engine? Can you turn the engine over manually by forcing the cam-shaft to spin, some bikes can do this with rear-wheel in gear and turn the wheel, if not then another way perhaps??

Again, apologies if you've already gone through all this, just not quite sure of the full story.
__________________
TurboCharger + Francois (our BMW R1200gs) '07
www.riding2up.net, blog.riding2up.net
Reply With Quote
  #7  
Old 7 Mar 2011
Registered Users
HUBB regular
 
Join Date: Apr 2008
Location: uk
Posts: 37
kle500a1 non start part 2

well this is what happened

1. had a sticking choke . freed this up with wd40
2. used some carb cleaner as well on the carb body and bell mouths . coughed and spluttered but cleared after a few seconds
3. stopped the engine . cleaned inside carbs with carb cleaner
4. now wont start . it has back fired a few times but now nothing not even trying
5. taken carbs off and cleaned and blown out . new spark plugs . checked timing all ok and float levels . good spark . turns over well .

since this i have changed the pick up coil this was out of spec . i have also checked all the wiring . (found 2 corodded wire going to fuse box ) now rectified . have cleaned and checked carbs 3 times now . all ok . i have a very good spark with plug out of the engine turns over ok battery fully charged . and plugs are wet when removed . the valves when checked were a little tight now sorted though . next plan of action is maybe compression test . see if i have a burn valve or ring gone (its done 57000mls) failing that maybe a gpz500 engine or replacement kle500 engine
Reply With Quote
  #8  
Old 7 Mar 2011
Registered Users
Veteran HUBBer
 
Join Date: Jul 2008
Location: Aussie expat in Switzerland half way RTW
Posts: 613
Maybe you could try some extra "hot" plugs like irridium or something. These might help blow out extra fuel in the cyclinders.

But given that the KLE is back firing you might indeed have a problem with a bad valve or piston rings.

Sorry I can't be more help.
__________________
TurboCharger + Francois (our BMW R1200gs) '07
www.riding2up.net, blog.riding2up.net
Reply With Quote
  #9  
Old 7 Mar 2011
Registered Users
Veteran HUBBer
 
Join Date: Sep 2008
Location: England
Posts: 152
Is the pilot screw set correctly? Is the choke adjusted properly? (cable)
Reply With Quote
  #10  
Old 8 Mar 2011
Registered Users
New on the HUBB
 
Join Date: Jan 2011
Location: tyneside
Posts: 17
right....don't bother looking for burnt valves or doing a compression check..you won't find the problem there.

i can almost gaurantee it'll be carb related..was running...took carbs apart...now not running...see where i'm going?

have you totally dissasembled the carbs and held each and every jet up to light to check they're clear?..if not do so...just blowing air through is not enough.

i suspect it'll be the pilot air jets blocked...and yes they are a bastard to clear.

make sure all carbs settings are as per the book..mixture screw,needle clip etc and the butterflys open together

years ago i had a mint rd250lc i bought cheap as it was hard to start...really hard as in 20 kicks might get it started ..went through all i could think of to try and sort it..gave up and sold it on...turns out the chokes were assembled wrongly..

where abouts are you in the uk?..maybe someone is close on the board who can help

EDIT: just thought..have you checked that one of the floats doesn't have a puncture?
Reply With Quote
  #11  
Old 8 Mar 2011
Registered Users
HUBB regular
 
Join Date: Apr 2008
Location: uk
Posts: 37
non start kle500a1

well i have the carbs apart again . all jets look clear . no crap in float bowl . levels ok . still have good spark and plugs wet . it does thump thump as its turning over as though its trying but theres no vapours coming out the exhaust . i have even tryed easy start again with the carbs on and off the bike . still nothing
Reply With Quote
  #12  
Old 8 Mar 2011
Registered Users
New on the HUBB
 
Join Date: Jan 2011
Location: tyneside
Posts: 17
lets get this right...you've tried easy start with the carbs off and just sprayed direct into the inlet port and it still ain't started?
Reply With Quote
  #13  
Old 9 Mar 2011
Registered Users
HUBB regular
 
Join Date: Apr 2008
Location: uk
Posts: 37
kle500a1 non start

yep that right . direct into the cylinder head intakes . this is why i think it may be compression or a valve . as i still have a good spark and the timing seems fine
Reply With Quote
  #14  
Old 9 Mar 2011
Registered Users
New on the HUBB
 
Join Date: Jan 2011
Location: tyneside
Posts: 17
try swapping the plug leads round.

putting the wrong leads on the wrong plugs is easy...done it myself a few times

i realise why you're thinking valves/compression but it was running before you took the carbs off,and you haven't had the cam out and had to set the valve timing it's unlikely...hell even if one cylinder had bent valves it would still run on the other.
Reply With Quote
  #15  
Old 9 Mar 2011
Registered Users
HUBB regular
 
Join Date: Apr 2008
Location: uk
Posts: 37
kle500 non start

plug leads are 2 short to swop over . so can b that .
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
part out :( KEtwoXT Yamaha Tech 3 21 Jan 2011 15:02
Who's taking part? Warthog The HUBB PUB 3 28 Mar 2009 23:30
Help need to identify this part bacardi23 Yamaha Tech 1 11 Apr 2008 22:10
3aj part number pgouvias Yamaha Tech 2 6 Jul 2007 09:03
BMW part nos. John Roberts BMW Tech 2 25 Jan 2005 06:24

 
 


HU DVD Summer Special!

Now that summer is here, get On the Road! Take 30% off the Achievable Dream - On the Road! 2-DVD set until August 31 only. Get On the Road! Learn the tips to staying healthy, happy and secure on your motorcycle adventure!

Our veteran travellers share their tips (and great stories) for staying healthy, happy and secure on your motorcycle adventure.

"A fantastic, informative and inspirational DVD."

"It's brilliant - thank you very much!"

Check it out at the HU Store! Remember to use Coupon Code 'ONTHEROAD' on your order when you checkout.


Renedian Adventures


Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!


What turns you on to motorcycle travel?


Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!


New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.


Books & DVDs

amazon

All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.


Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!




All times are GMT +1. The time now is 04:54.