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Old 10 Apr 2015
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Help tuning old KLE

Hello all,

Hoping to get some help/ideas about tuning my geriatric KLE 500. Its a 92 model and having done a general overhaul I am now trying to iron out what seems to be a persistent carb issue.

The bike rides fine when cold but as it heats up it starts to die when taking off from stationary and has a hesitation at low throttle. It also is slow to return to idle once hot.

This article leads me to think this is a fuel level issue:
CV Carb Tuning Procedures

Unfortunately the only manual I can find is for the 06 model (I think) so I'm unsure whether the settings are the same for the older model - read that some people had found a German manual for the older KLE (can anyone send it to me? Please!). But figured I would use the adjustments in the manual I have as I dont have anything else to go on.

However I have checked the float level and increased it to the maximum suggested in the manual, 19mm and have both pilot screws set at 1 3/4 turns - as manual advises.

So questions:
1. Does anyone know the float height and pilot screw adjustments for the 'old' KLE? (or have the manual?)
2. Any ideas of where to go next - assuming the float height and screw are correct.

Things I have done:
  • change plugs
  • change coils
  • change throttle cable
  • strip and clean carbs
  • change float needle

Next on my list is to balance carbs and maybe try various settings on the screw failing that maybe getting a colortune and seeing if it will tell me anything.

Be very grateful for any thoughts!
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Old 2 Jul 2015
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Join Date: Oct 2008
Location: finland
Posts: 57
seems like mixture is too rich? Choke is jammed?
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