Preflight check

Posted: 16/09/2014 in Repair archives

Hey all!

As I have stated in the my bikes post, I have recently bought a KTM LC4 640 Enduro. And like with all second hand motorized things I buy, I always preform a complete check of the bike and do a service on it. So after having a bike for 2 weeks, I have done the following things:

Changed the brake pads, as the ones on the bike were under the service limit, and brake fluid…IMAG0308

…next on the list was the radiator hose that was leaking, and it still leaks after the change, and coolant…IMAG0304

…also the battery needed to be changed…


…I have found a broken KTM Powerparts filter cover, so I ordered a new one, but instead I got a OEM gasket and plastic cover…



There are a few more things to do, I still have to clean the air filter, I am thinking of just getting a new one as this one might still be the OEM one installed 12 years ago…


… and get a new tachometer cover (those things are really expensive), as the buttons are chewed up and water can get inside..IMG_4509

Also I have a new spark plug ready to go in as soon as I get a proper tool to remove the old one.

Stay safe and keep an eye out on the blog as I have quite a few things to post up!


Posted: 31/08/2014 in Uncategorized

Hey all!

I have to tell you that on this site there will be no more new mods, upgrades or services of KLE500 as I have recently sold it. It came to this through some complications and changes in my life. Don’t worry though, this blog will stay, all the contents will still be available and new posts will come up, but it will be of a different bike. Hope you all find something interesting on this site.

Here are the last 2 pics of the bike before the owner rode away

I am still deciding on the next bike, I know it will be a 650 thumper, so far I have my eye set on 650XChallange and XR650R. We will see what happens.

Stay safe!


Today I have something special for you. I have a short post about how to get rid of all that ECO stuff on your bike and make the engine bay a bit less cluttered.

We will be removing the so-called PAIR system. Now what is PAIR system? The PAIR system works by injecting a small amount of air into the exhaust system to help keep the combustion process going. It therefore burns up more of the gasoline that was not previously burned in the combustion process inside the cylinder. It does this via a small air pump that pumps the air into a fitting on top of each valve cover.

What you need for this conversion can be bought straigth from your Kawasaki dealer, as this system wasn’t on the pre 2005 KLE’s those parts are readily available.


Here is what you are going to need:
-2x CAP Part Nr. 110121212
-2x REED VALVE GASKET Part Nr. 110091879
-1x PLUG Part Nr. 920661321
-1x PLUG, RUBBER Part Nr. 92068006

And like with all the things you do on your KLE, you first have to remove the tank.

Here is a picture of the engine bay before removal of the system. Notice that big silver thing in the middle and the hoses attached to it? Those are the things that will be removed.

It is a dirty job, and it will take quite a while to do since you have to remove the engine bars if you are using SW-Motech’s. And you could use someone with small hands as there is a tight fit to plug up the airbox hole.

After some fiddling around and bolting everything back together, this is how it looks all buttoned up.

And what are the benefits of this modifications? Well for starters, there is more room for accessing spark plugs and you get rid of popping out of the exhaust, which is great if you are trying to hide while ridding off road in a country that doesn’t allow it.

Here is what you end up with after removing the PAIR system.

That is it for today, hopefully next week I will have a ride report to post after a whole month of rain.

Stay safe!


After abusing my MadHead handguards for 6 years (3 on Varadero and 3 on KLE), it’s time for a replacement. If you remember, I have made a post about which handguards fit KLE’s handlebars here. But since I have changed OEM bars for Renthal’s this isn’t a continuation of that post, though those guards are listed as a fit to OEM bars.

So a while ago I ordered a set of new handguards for my bike. I had to wait quite a while for my package to arrive and in the package was this

Yes you see correctly, I have orderd a set of Barkbusters handguards. They sure are expensive as hell, but I have seen them take a lot of abuse without braking so I thought I would be a wise buy. Here are the part numbers for a 22mm (7/8 inch) handlebars:
-BHG15-01 aluminium backbone
-BHG3-OR-WD plastic VPS guard with variable wind deflector
-BHG2 Skid plate for alu backbone

Here are all the plastic parts, they were individually wraped in plastic with all the bolts needed

And the aluminium parts with its hardware. These guards are really beefy, they are made out of 10x20mm aluminium bar.

The installation was easy and fast, but it would have been faster if it wouldn’t be up to KLE’s clutch cable. But more on that later. Here is one new and one old handguard.

I couldn’t decide if I want to have the wind deflectors on or off, so I tried one side out and see how it looked.

And I have decided to keep the wind deflectors on high setting.

Here is the troublesome clutch cable. That metal bend is really bugging me. I will order a custom cable some day, without that miserable bend in it.

No problems on the throttle side.

All finished up.

I am sorry for bad pictures, I only had my phone to document this as my camera has died. Once I get it fixed I will post some better photos of the bike outside the garage.

But until then, stay safe and happy riding.

Enguro 2014

Posted: 13/07/2014 in Ride reports archives


On a weekend from 4.-6. July I was in Bosnia on a first time event called Enguro. It was held on a old military airfield in Banja Luka. I have teamed up with 2 other riders from Slovenia, but due to unfortunate circumstances, only two of us made it to Banja Luka.

The day started out quite interesting. After only 400m from the point of meeting the other 2 riders, I got a flat tire.

So 2h after me getting a flat tire, we were finally back on the road heading south. After getting past Zagreb in Croatia we have hit some dirt roads.

We have hit 2 dead ends, one would be ridable if we wouldn’t have been loaded with panniers and camping gear. But we have turned back and headed to the border on road.

Here we have encountered a problem. Our leader has forgot his bike papers and green card at home. So he couldn’t cross the Bosnian part of the border. So only 2 of us could carry on. We have arrived at the destination at 20:30 in the evening. Here is our HQ in the morning before the ride.

There was around 30 of us there, the bikes varied from KLE’s, TTR’s, XT’s Africa Twins, Super Teneres,… As many as there were bikes, there were different tires. From full knobbly tires to slick road tires. Here was a quick stop after a steep and technical decent.

The rest of the terrain varied from fast gravel roads to rocky technical trails.

Midday we took a brake on a river bank, to which only a handfull of us have descended as is was some steep and slippery rocks.

After lunch, we were riding in between 2 mine field’s but unfortunately I didn’t took any pictures of it :( But I have a picture of how to get around a big obstacle blocking the road. There were 2 wood trucks on the road and we had to make a detour through some thorns.

The Enguro trail took it’s tool on some bikes

And that is how the day ended. On Sunday morning, we have saddled up and hit the road home. We took a road less travelled on our way to Kozara national park.

Just before the border we took our final brake.

All I have to say is that it was really a great weekend. From riding to drinking and meeting new and old friends. Hopefully there will be a part 2 of this event in September as it was rumoured by the organisers.



As we all know, KLE has quiet a uncomfortable seat for long rides. And because of that I have ordered a gel pad. It took me a while to find the time to open the seat up and cut out the foam, but it was a easy job anyone can do at home. Here are a few pictures with a few pointers on how to do it.

First lets make one thing clear, I did not reshape the whole seat or the cover, I used the original cover and foam was just cut out to accept the gel pad.

List of needed tools, etc…
– Gel pad of your choice
– Staple gun (high powered electric or pneumatic unit, seat plastic is really hard and a gift warping staple gun is not strong enough)
– Flat head screw driver
– Needle nose pliers
– Very sharp knife
– Sand paper
– Black marker
– Spray glue

First of all you need to decide where on the seat you would like to have the gel, where is your position when riding.

Than use a flat head screw driver and pliers to carefully remove the old staples without tearing the cover

You don’t have to remove the whole seat cover, only remove enough staples so that you can pull the cover back to have enough space to work on

Now that you have exposed your foam, draw a grid on it, where you will have you gel pad. It is important that you make it as central as possible so that the gel won’t be to far on one or the other side

Here is the point of no return, the first cut in to the foam. From here on you need po be very careful when removing foam not to remove to much. Its easy to cut foam away, but a lot harder to add it back on

Work your way around the foam, until you get enough of it out to fit your gel pad. After roughly cutting the space, smooth it out with some sand paper

When you are happy with the smoothness of your foam, spray some glue on the gel pad and on the foam, than press them together firmly

After the glue has cured, you can reinstall the cover. First stretch it to the front, make it nice and tight. Than go and staple the sides back on and your done

Now you are ready to put the seat back on the bike and enjoy your new seat.

So after a few long rides I quite like the gel pad, it take around 45 min to 1 hour more until my back side goes numb and I have to stand up for a while. But it was worth the time and work involved.

Stay safe!

So as I have described in the previous post, I have attended a enduro event in Croatia. And in this post I will try to look back at the event, and talk a little of what I have experienced there and so on.

First thing that will stay in my memory for the riding days to come is an advice that I got from one of the riders: “When in doubt and things start to go wrong, just open the throttle”. And I must say that opening the throttle saved me a lot of times from picking up the bike in hard parts.

Next observation I made was that getting drunk the night before the ride, waking up with a hangover and climbing on a 200 kg beast of the bike isn’t the best combo :)

Moving on to the bike. I must say that I was really surprised that I could keep up with the smaller bikes and more experience riders with my KLE, and that the KLE didn’t fail me. My biggest worry was that I would had some mechanical brake down. But the worst thing that happened was a bent shifter lever after a spill in mud. this picture was taken after field straightening, before it was bent complete 180 degrees to the foot peg. IMG_4375

Luckily the KLE shifter pedal is made out of some soft steel insted of aluminium (it would snap off). So I took it to work with me straighten it out and had it painted black, this kind of paint should stand up good to all the rocks and debris as we use it to paint pneumatic rock drills and hammers. Also I have checked at Kawasaki dealer for a new part and they wanted 70€.

The front suspension handled really well, and soaked up the bumps without throwing me off course. At the end of the day there was still some room left to move on the forks and the wheel never hit the front fairing. Overall I couldn’t be more happy with the front end of the bike, it was really worth all the work and money spent on it. There was approximately 40-50 mm of unused travel, which translates to around 250-260 mm of the 310 mm travel was used.

I think that KLE covered in mud looks quite good. Do you agree?

Other things I have found out on the bike that needs some attention in the future:
1. Get some sort of folding mirrors. Not because I am afraid of breaking the OEM ones, but to get them out of the way when riding off road.
2. Carry pressure gauge with me and appropriately change tyre pressure depending on the terrain. I don’t want to ride off road with that much air in my tyres again.
3. Remove the front wind screen as it is tinted and in shadowy forest you can’t see s*** through it.
4. Get some new handguards ans those are pretty beaten up after 3 years on Varadero and 4 years on KLE.
5. Sort out the rear suspension. Though it isn’t as bad as the OEM forks were.
6. Put KLE on a diet :)
7. Don’t drink to much the night before riding :) :)

I guess a project bike like this there is always something to do on it. But the bottom line is, I have really enjoined attending this event with KLE, meeting new people and I will be going to other similar events for sure.