New KLE500 Clan Member

[Shaun500]

You can get 270km out of a tank.Done it.But then you really have to take it slowly.

That's only commuting.  High speed touring I get about 220 km.

[Carl84]

I get about 240km before reserve commuting. I have a 2006 Kle however have fitted the jets of the older model, think they are 112. Also have bigger old snorkel on the air box.

Sent from my MZ604 using Tapatalk

[Titanic]

These are lovely bikes. I searched for about 6 months for 2nd crashbars, but could not find. Eventually I had to put in a special order and had to wait approximately 4 months for them. It was SWMotech and they were around R2500 a set.

[Shaun500]

I get about 240km before reserve commuting. I have a 2006 Kle however have fitted the jets of the older model, think they are 112. Also have bigger old snorkel on the air box.

Sent from my MZ604 using Tapatalk

I've gone full circle with the jetting.  I tried the old models 112 jets and different needles, together with the rimfire airbox mod with larger snorkel and DNA performance air filter.  The fuel consumption was terrible and driveability wasn't really that great.  It was far to rich.  I'd get about 220 km until reserve...and that's only commuting  .  I found that stock air filter with two 6mm holes and mildly tuned carb (98/100 jets) worked best.  At least at coastal altitude. The backside dyno doesn't lie 

[Carl84]

I can relate!

I had my bike "professionally" dyno tuned by a place in Centurion - what they ended up doing was installing 135 main jets and removing the snorkel completely and running the bike without the front airbox cover (where the snorkel plugs in). On the dyno the power looked good but taking it out on the street, what a disaster! That open airbox caused big hesitation especially when going off throttle at 100kph and then opening the throttle back up. Obviously the CV carbs need some sort of airflow restriction to work properly. Also fuel consumption was not good at all.

[Ysman]

200km to reserve is about right.

I get on average 270 km before reserve (12L) commuting.  Like I mentioned I have had some mild jetting done on the carbs (98/100 mains).  The air filter is standard but has two 6mm hole in the airbox for better breathing.  The air screw is tuned out about 2 and three quarter turns out.  With a free flow pipe the bike tends to run even leaner than it does with a standard one.

Wow 270km before reserve is very good! Certainly that must qualify  for one of the best fuel efficiencies for a KLE out there?

Can anyone equel or beat that??

[Ysman]

These are lovely bikes. I searched for about 6 months for 2nd crashbars, but could not find. Eventually I had to put in a special order and had to wait approximately 4 months for them. It was SWMotech and they were around R2500 a set.

Yeah reading previous threads where people were looking for 2nd hand crash bars didn't seem promising.
Think I'll just get new ones...

[Shaun500]

I can relate!

I had my bike "professionally" dyno tuned by a place in Centurion - what they ended up doing was installing 135 main jets and removing the snorkel completely and running the bike without the front airbox cover (where the snorkel plugs in). On the dyno the power looked good but taking it out on the street, what a disaster! That open airbox caused big hesitation especially when going off throttle at 100kph and then opening the throttle back up. Obviously the CV carbs need some sort of airflow restriction to work properly. Also fuel consumption was not good at all.

CV carbs can be a bitch to tune properly.  Altitude, rate of air flow, fueling etc. all have a big effect.  The common mistake most people make is sticking on K&N pod filters directly on the carbs and doing away with the air box.  It never works properly and the fueling is all over the place.  CV carbs NEED an air box to get the balance right.

[Ysman]

So, on my next tank of petrol I got 199 km until reserve and a total fuel consumption of 17.79 km/L until just before empty.
No great at all. But there is hope.
Some experts are of the opinion that I can expect better fuel efficiency when using a stock exhaust, especially due to the extra couple of holes in the air box.
These extra holes are a result of the Tornado exhaust conversion the previous owner had done.

As stated in a different thread, I was looking for a standard zorst as the Tornado was just to loud to my liking. And most probably the neighbours in a 2 block radius.

Anyways, a fellow dog was willing to part with his standard zorst.
I received it last week and had it fitted last Saterday and took a couple of pics 

[Ysman]

The exhaust exchange was conducted at Noise Boys Silverton, and I must say, I'm very pleased with the service and level of competency.
When realising they were not going to take of the whole exhaust system but just operate as is, I got a bit nervous.
How do you cut of one zorst and weld on another without damaging the bike??

To following pics show the sequence of events...

[Ysman]

The dismantling started...

[Ysman]

I wonder what that would sound like...

[Ysman]

Now for the new zorst.
I was quite relieved when after some cutting and grinding the Joe came back with the standard pipe and it all seems to align nicely 

[Ysman]

Welding it together. Had to be done from two sides.

[Ysman]

The final product!  I like the look of the standard pipe a  lot more 

However, over the past couple of weeks a kind of got used to the sound of the Tornado pipe.
While riding home, although the new pipe does have an appealing sound to it, it very much sounds like the growl of a wild dog that has lost one of his balls in fight somewhere.
The growl has a little bit less gusto   

Anyways, I'm happy. The neighbourhood is happy.
And if I ever need to pull a Swart Kat or Straatvalk stealth mode for whatever reason, now I have that option available   

[Oubones]

The final product!  I like the look of the standard pipe a  lot more 

However, over the past couple of weeks a kind of got used to the sound of the Tornado pipe.
While riding home, although the new pipe does have an appealing sound to it, it very much sounds like the growl of a wild dog that has lost one of his balls in fight somewhere.
The growl has a little bit less gusto   

Anyways, I'm happy. The neighbourhood is happy.
And if I ever need to pull a Swart Kat or Straatvalk stealth mode for whatever reason, now I have that option available   

Looks neat.
You just need a nice screen and time to ride.

[SmuGS]

Regarding the exhaust, here is my mod..

http://www.wilddog.za.net/forum/index.php?topic=167247.0

[Ysman]

Thanks. Yes I agree. I'll read the posts again and will make an attempt at a bigger screen. One that is see-through 

[Ysman]

Regarding the exhaust, here is my mod..

http://www.wilddog.za.net/forum/index.php?topic=167247.0

SmuGS, I would be keen to know what your KLE sounds like with that exhaust fitted.
Great welding job! The new pipes compliments the bike.

[SmuGS]

Ja the KTM exhaust is probably not as loud as the Tornado pipe you had but it has a bit of bark to it when you wind the bike up. I also live in a complex so have to keep the neighbors happy. The SX exhaust is louder than the EXC which is more restricted. I also have a Scorch pipe which I tried but that was way too loud, basically a 50mm straight through pipe..