A while back, my bike has developed a fault. While kick starting it, e-motor and all the gears were turning with it. It surely didn’t sound healthy.

So I have started investigating the problem. After talking to the guys at advrider.com I have been advised that the sprag clutch is probably stuck in engaged position. So before we head into the process itself, lets look at the tools and parts you will need.

Tools:
– 8, 19(puller screw) and 24 socket
– 32 wrench, at least for my custom magneto puller
– magneto puller, KTM part nr. 584.29.009.000

Parts:
– new gasket, KTM part nr. 584.30.040.000

Here is the puller that they made for me
IMG_4543

So we have started wrenching with the bike on its side. I have put a log under the handlebars. A fret taking 4 bolts (8 socket) out of the case you can simply lift the cover off. But be careful no to tear any of the cables.
IMG_4544

Once the cover is off, this si what you will be looking at.
IMG_4545

To undo the nut you will need a 24 socket. Also it is a right hand thread, so you un-tighten it with turning it right. After that you screw on a puller. At this time I have put the bike up on its side stand as it was easier to undo the nut, fortunately no oil got out.
IMG_4546

After pulling everything off, I have found out that the spring was torn in a few places.
IMG_4547
IMG_4553

After cleaning the debris of the spring out of the bike and off the magnet, I have reassembled everything back in reverse. I kicked it a few times and it started up nicely. The only drawback of this is that I now don’t have a e-starter on my bike.

Stay safe!

After a slide

Posted: 28/09/2014 in Repair archives

So on Tuesday, I have taken the bike for a short spin after a workout session on the kick starter. It was one of the few days that we had sun this week, so I put my boots, helmet and gloves one. I pinned the throttle up the nearest hill that had just recently been paved, they ruined one of my favourite gravel roads in the area. So I got to the top, had a few minutes rest and than headed back down. On the way down I always go slow as you only have your brakes and railing to to stop you.

But today, going down, was a bit of a problem. In one of the turns, at 20-30 km/h, I have hit a patch of some lose gravel/sand on the pavement and lost the front end of the bike. It was like I have hit a ice patch no chance to keep the bike up.

So after sliding on the pavement for around 15m in jeans and a long sleeve shirt I have come to a stop with the bike upside down, leaking fuel and me leaking blood.

A quick check of myself, and other than being peeled like a banana on my left knee, both elbows and right hip, I checked the engine for any cracks in the sump guard and any other major damage and luckily the worst damage was a broken shifter lever.

Before the pain sets in, I kicked the bike and rode to the garage, took a few pictures and went home to take a shower and clean the wounds. In the end I ended up at the ER and on the pills for a week…

Lets focus on the bike. Here are are a few pictures of the bike
IMG_4534
IMG_4536
IMG_4537

Luckily for me the KTM dealer here is fast and I got the new shifter lever in 3 days, but the price really high a 54€+ delivery. New and old. I will get the old one welded to have it as a spare.
IMAG0352

I won’t bother with the rear plastic as it will get even more scratches as I start ridding off road, as for the handguards I have a set of Barkbusters from my KLE ready to go on.

Ow well, I think I will be going on a rides from now on in full riding gear.

First good ride

Posted: 26/09/2014 in Ride reports archives

It was a nice, beautiful, partly cloudy Saturday. It showed like it could start raining, but I didn’t care. I have saddled up my bike and went for a few hour ride. I have set off towards Pavličevo sedlo, through Austria. This route would give me the best conditions to test the bike out on twisty pavement and some gravel roads.

The view from behind the bars
IMG_4518

A lonely rode in a lonely world
IMG_4519

Taking a break on the way up
IMAG0317

It was a good ride up, but as always, what goes up must come down. So I have started my descent towards the border and Solčava valley.
IMG_4521

I have taken a quick look into Logarska valley, but the view isn’t that great as it was really cloudy.
IMG_4522

In a small town of Solčava I have stopped for a quick cup of tea as it was really cold on the KTM. They have a really nice tourist centre called Rinka, it is worth a visit.
IMG_4526

After getting my core temperature back up, I headed back up in to the hills, over to Črna. In a few kilometres out of town I have spotted something interesting just by the road. It looked like someone was carving a bear out of the log.
IMG_4528
IMG_4527

When I have got on the gravel it quickly got really interesting. I thought I knew how to ride off-road but my beast has quickly proved me wrong. But I have to say that the bike has a used Metzeler Sahara front tyre, to low bars for sanding and it is much lighter than KLE, so I guess it rides differently that what I used to from KLE.
IMG_4530

With a few more minutes back to the house I have looked up and didn’t like what I saw.
IMG_4531

Hopefully the weather has held up until I got to the garage. It was a nice day for riding and I really had a good time. Riding really is the best medicine for clearing your head.

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…

IMG_4508

…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…

IMG_4505

IMG_4517

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…

IMG_4506

… 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!

Announcement

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
IMAG0281IMAG0282

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!

Hey!

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.

IMG_4486

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
IMG_4487

And like with all the things you do on your KLE, you first have to remove the tank.
IMG_4488

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.
IMG_4489

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.
IMG_4495

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.
IMG_4497

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

Stay safe!

Hey!

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
IMAG0240

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
IMAG0255

And the aluminium parts with its hardware. These guards are really beefy, they are made out of 10x20mm aluminium bar.
IMAG0256

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.
IMAG0259

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.
IMAG0260

And I have decided to keep the wind deflectors on high setting.
IMAG0261

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.
IMAG0262

No problems on the throttle side.
IMAG0263

All finished up.
IMAG0267

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.