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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 http://inlinethumb32.webshots.com/44...600x600Q85.jpg http://inlinethumb31.webshots.com/13...600x600Q85.jpg http://inlinethumb11.webshots.com/47...600x600Q85.jpg http://inlinethumb46.webshots.com/47...600x600Q85.jpg http://inlinethumb45.webshots.com/47...600x600Q85.jpg http://inlinethumb27.webshots.com/49...600x600Q85.jpg After powdercoat http://inlinethumb48.webshots.com/49...600x600Q85.jpg http://inlinethumb61.webshots.com/25...600x600Q85.jpg http://inlinethumb07.webshots.com/49...600x600Q85.jpg http://inlinethumb50.webshots.com/46...600x600Q85.jpg |
Congrats for the beautiful frame color.
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I love these sort of threads, more pictures and descriptive please bier
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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 |
That looks fantastic!
I've been thinking about stripping mine down and doing the same. Any top tips for things to look out for ? |
http://inlinethumb18.webshots.com/47...600x600Q85.jpg
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. |
Nice coloro of the frame, like it very much, keep the pictures comming :thumbup1:
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:thumbup1::thumbup1: |
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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 :cool4: Some more progress from the weekend http://inlinethumb62.webshots.com/48...600x600Q85.jpg http://inlinethumb21.webshots.com/49...600x600Q85.jpg http://inlinethumb18.webshots.com/47...600x600Q85.jpg http://inlinethumb46.webshots.com/49...600x600Q85.jpg http://inlinethumb34.webshots.com/47...600x600Q85.jpg http://inlinethumb36.webshots.com/28...600x600Q85.jpg http://inlinethumb01.webshots.com/47...600x600Q85.jpg http://inlinethumb02.webshots.com/49...600x600Q85.jpg And some teaser shots http://inlinethumb41.webshots.com/47...600x600Q85.jpg http://inlinethumb39.webshots.com/48...600x600Q85.jpg |
?c? That red frame fits really nice with the gray fairing, now only crash bars need to be red:cool4:. Nice project, keep the pictures comming :clap::clap:
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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.:taz: |
Bit of a late update
Heres last couple of weeks progress http://inlinethumb62.webshots.com/47...600x600Q85.jpg http://inlinethumb36.webshots.com/48...600x600Q85.jpg http://inlinethumb11.webshots.com/49...600x600Q85.jpg http://inlinethumb38.webshots.com/50...600x600Q85.jpg http://inlinethumb10.webshots.com/49...600x600Q85.jpg |
It looks like more like a KLE after each post :clap: 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.
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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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inspirational!
I've been inspired... I've now got a KLE in kit form, 1001 rusty or oily pieces. I'm hoping to send the frame for blasting and powdercoating next week, but I'm not sure I'll go for as brave a colour scheme as yourself !!
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In hindsight in terms of durability i think a standard flat colour would be a better choice as the colour i have chosen is 2 stage powdercoating (silver base coat and transparent red top coat) and is easily damaged as the top coat can't really key in to the smooth base coat it just chips off or cracks with a small amount of pressure
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That is one good looking KLE:thumbup1::thumbup1: I really like that red frame and handelbars. Can you please tell me the dimensions of the bars? I have nooticed you mounted high fron fender(which looks good on any KLE :cool4:), what cought my eye was the engine protection. Can you tell me anything about it(material, measurements, fitting,...)? Been thinking of this kind a protection for my KLE too.
Thanks, Ghosty! |
Thanks
The bars are 5.0" Renthal trials bars if i recall 7/8 Handlebars: Applications= The engine plate is just something i made out of a bit of 1.5mm aluminium chequer plate it really helps keep the front of the engine clean and stops the bash plate filling with mud when offroad. |
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Doesn't a plate cover to much engine and prevents cooling? How aobut useing some sort of metal mesh, something simmilat to radiator guard but more heavy duty? |
The cables were long enough but only just.
As for cooling it seems to be fine but i only have it on over winter, summer riding or trackdays i take it off cuz it probably would cook itself if i didn't |
Do you think the cables would be long enough to put on a 6.0" raise handelbars?
Thanks for all your info and help! |
Clutch cable might be ok but not sure about the throttle and choke cable your best bet would be to take the tank off and have a check and see how much slack there is, keeping in mind when you turn the bars there is less slack
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Hey!
Sorry to bother you again with questions about handelbars. Do you know any measurements of the original bars? Are those 5.0" you mounted on your KLE any higher than original? If so, how much higher? Thanks for your help! |
If i remember correctly the Renthals were roughly the same as OEM just with less sweep angle.
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Great job there, really inspiring, congratulations.
Noticed a 800GS in the picture above, how do the two bike compare to each other both on and off road ? |
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Well aside from the obvious the GS accelerates and brakes better and has better suspension. On road i find the geometry of the KLE is better it turns in alot quicker and once you get used to the suspension moving it is pretty much on rails it never lets go even when your leaning so much that you grind out the pegs, brake pedal and skidplate (Trackday at mallory park). The GS on the other hand while it will easily match or better the KLE when cornering it always feels like it is pushing the front too much and doesn't feel so secure nearly tucked the front at a fast junction but somehow pulled it back. Economy the GS wins easily although the KLE is tuned so not a big surprise Offroad i've never had the same tyres on both so hard to compare. Slow technical stuff i would say the KLE is best its lighter and throttle is less snatchy, faster bumpier stuff the GS is better the suspension copes better and engine has more torque, the KLE is limited by its suspension it crashes about and the exhaust bottoms out easily Personally my ideal bike would combine the looks, suspension, brakes and power of the GS with the geometry, weight, simplicity and sound of the KLE |
Hi Shaun,
Thanks for the reply, I am a big fan of the KLE500 although when I was looking for one last year I was seduced by the KLE650 engine and have been moding the bike to a more adventure type bike with 19" front wheel and a bit more suspension travel but not as much as the KLE500. Am off to Morocco in a week with a mate on a F800GS so it will be interesting. I rode my mates F800 and agree about the front. I wonder if the 650 engine would go in the 500 frame, it is a pity Kawasaki doesn't do something like this, they have all the bits, KLE500, KLR650 and the KLE650. Cheers |
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