Author Topic: My pooratec mods and prep work I have done to my KLE500 for my Namibia trip (Read 2062 times)

Fuzzy Muzzy · « **on:** March 16, 2018, 01:02:21 pm »

When I got my KLE it was in pretty good condition but it was nowhere ready for a good 14 day trip through Namibia.

The list of things I did just to prep

Change the speedo , clutch cable
Made up pannier racks
Changed the tail light to LED / changed rear indicators to LED and changed their position.
Added a 12V socket
Had the seat reshaped and recovered
Added in a tool tube and 5L fuel solution
New tyres ( E07 front and back ) / chain / sprockets ( 17 front 44 rear) / oil / oil filter / brake pads

This was my 1st attempt at packing the bike just to see where everything would go

Fuzzy Muzzy · « **Reply #1 on:** March 16, 2018, 01:05:10 pm »

Time for the panniers to get bent up and welded on , a massive thank you to Glenn who sold me the bike for helping out with this, the man is a genius and bent these up in no time.

Fuzzy Muzzy · « **Reply #2 on:** March 16, 2018, 01:07:44 pm »

While it was open like this the electronics are really easy to get to, so most of the wiring came out and got redone.

Indicators got changed out to really small ones and changed the position so that they are more visible with a load.

Fuzzy Muzzy · « **Reply #3 on:** March 16, 2018, 01:09:43 pm »

Sadly the more you work on bikes the more you want to change and mod, but with this bike we showed some restraint, just doing what needed to get done

More pannier work and 12v socket installed with inline fuse.

Fuzzy Muzzy · « **Reply #4 on:** March 16, 2018, 01:12:00 pm »

This was the 1st attempt at placing the fuel tank and tool tube, thankfully no adjustments were necessary.

Kelevra · « **Reply #5 on:** March 16, 2018, 01:12:06 pm »

Fuzzy are those bracket connected to the swing-arm directly?

EDIT: never mind I see now its the rear footpeg bracket

Draad · « **Reply #6 on:** March 16, 2018, 01:13:02 pm »

looking good but if I may ....weld some support in here

Fuzzy Muzzy · « **Reply #7 on:** March 16, 2018, 01:13:17 pm »

The back light was crap so tossed it and replaced with 2 layers of LED, one for park and one for brakes.

Fuzzy Muzzy · « **Reply #8 on:** March 16, 2018, 01:14:47 pm »

Quote from: Kelevra on March 16, 2018, 01:12:06 pm

Fuzzy are those bracket connected to the swing-arm directly?

No, they are attached to the brackets, Ill take some close up shots tonight, im only doing final assembly tonight and packing tomorrow, we leave on Sunday

Fuzzy Muzzy · « **Reply #9 on:** March 16, 2018, 01:15:48 pm »

Quote from: Draad on March 16, 2018, 01:13:02 pm

looking good but if I may ....weld some support in here

I looked at doing that but i thought it was starting to become overkill

just came back from powdercoating

Kelevra · « **Reply #10 on:** March 16, 2018, 01:16:24 pm »

Quote from: Fuzzy Muzzy on March 16, 2018, 01:14:47 pm

Quote from: Kelevra on March 16, 2018, 01:12:06 pm
Fuzzy are those bracket connected to the swing-arm directly?

No, they are attached to the brackets, Ill take some close up shots tonight, im only doing final assembly tonight and packing tomorrow, we leave on Sunday

Yip, saw that after a closer look..thought for a moment you want to disable your rear shock

Draad · « **Reply #11 on:** March 16, 2018, 01:18:27 pm »

I only just saw the bracket going to the front for support ...Plenty there so I would not worry

Really looking good ....when we leaving

Fuzzy Muzzy · « **Reply #12 on:** March 16, 2018, 01:18:41 pm »

..I made the mount out of an old tripple clamp, , sadly I wont have time to test this actually works before we leave but I think, based on other mounts ive seen in production that it will be fine. Time will tell

Fuzzy Muzzy · « **Reply #13 on:** March 16, 2018, 01:21:17 pm »

Quote from: Draad on March 16, 2018, 01:18:27 pm

I only just saw the bracket going to the front for support ...Plenty there so I would not worry

Really looking good ....when we leaving

Ba ha, leaving Sunday morning. Got to go pick up the seat, speedo cable and still change oil.. leaving it tight but i keep adding things and changing things, this whole mod has taken 2 weeks, my Transalp is still being worked on 2 years later.. the OCD is strong .

desertfox · « **Reply #14 on:** March 16, 2018, 01:26:59 pm »

Black_Hawk · « **Reply #15 on:** March 16, 2018, 01:36:15 pm »

Looking good FM. JOb well done

Enjoy your trip

hje · « **Reply #16 on:** March 16, 2018, 06:17:15 pm »

Looks good !

Enjoy, have a safe trip

Will be waiting some good pics

Shaun500 · « **Reply #17 on:** March 16, 2018, 06:22:04 pm »

It looks really neat. Have a great trip.

...I hope you sorted out that KLE seat, they are notoriously uncomfortable. I did a trip to Port Alfred in one day on my KLE a while back. Iron butt doesn't even begin to describe the agony

NoRush · « **Reply #18 on:** March 16, 2018, 07:34:22 pm »

Nice work on the soft pannier brackets, looks really sorted. Enjoy the trip.

Oubones · « **Reply #19 on:** March 16, 2018, 08:32:04 pm »

Looking good, enjoy and safe travels.
Waiting for the RR when you are back.