It's in

[stinkwheel]

Got that GPZ500 engine in the KLE and running today. Started fitting it at 12.30 today, just got back inside after a brief test-ride.

Actually managed to lift the engine in by hand and balance it there while I slid the bolts home.

The CDI wasn't too tricky to wire in either although as it turns out, the coils are the opposite way round. Had the ignition timing 180 degrees out on the first attempt, just a case of swapping two connectors round though.

Other buggeration factors were pretty minimal. I accidentally left the o-ring off the old oil filter on the e4ngine and put the new one on top of it with the net result that the bike spat out about 2 litres of oil in a second when I blipped the throttle. At least there are no worries about the oil pressure.

It isn't running right, but it is doing exactly the same as the KLE was when I put the same set of carbs on. Pulls like a train up to 7k hesitates, pulls through then totally runs out of steam at about 8k. I'm convinced it isn't getting fuel, not sure if it is a problem with the carbs themselves or if the fuel just isn't running out of the tank quickly enough.

I'll put the KLE carbs on it tomorrow and have another tinker with the GPZ ones.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[colin1]

i guess this sort of thing is a good reason to have a 500.

Im guessing things wd have been more tricky on a modern 600.
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colin1 is officially faster than god

[phantomtek]

Good job Stinkwheel.

[stinkwheel]

[Paul@125power]

I had the same problem when experimenting. I found that thinking in of term of not enough fuel was wrong..think of in terms of air!

By this I'm no trying to by condescending

I just have moral thought about teaching and learn
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If at first you don't succeed.....destroy all evidence that you tried.

Yamaha YQ100 (RIP)......Honda CBR125R

[stinkwheel]

[quacker_boy]

[carlnicholson...]

Do you think the GPZ motor will put out anymore horses than the KLE?

My KLE is the '05 model (and bunged up with 3 cat converters) and is a fair bit slower than I thought it would be. Hoping to put a stainless pipe on it sometime, but I'm a little worried about when MOT time comes round in a couple of years!
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"THOSE WHO RISK NOTHING, DO NOTHING, ACHIEVE NOTHING, BECOME NOTHING."

[Richy]

[stinkwheel]

According to the book, a KLE makes 50bhp and a GPZ500 makes 60bhp. One always has to take what the Japanese claim their bikes do with a pinch of salt though, they are notorious for lying about it.

That said, having ridden both, the GPZ is certainly a lot more peaky, revs higher but with a much flatter midrange.

Laser make a 'pro-duro' stainless exhaust system for the KLE with a choice of either a road legal or a sports can. I got the sports can which sounds great, but it is rather noisy. I know I have no problems with the MOT because the guy that does my testing has exactly the same can on his bike, others may not be quite so impressed.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[carlnicholson...]

It's the emissions I'll have bother with I think. Getting rid of all the cats would give it much more shove, but may pose problems for it's first MOT. It is 2 years away, but I will almost certainly still own it then.

Bloody europe sticking their beaks with emissions.
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"THOSE WHO RISK NOTHING, DO NOTHING, ACHIEVE NOTHING, BECOME NOTHING."

[impaler]

Correct me if I'm wrong, but I thought there was no emissions testing for a bike MoT? Volume is another problem altogether, of course.
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Monster m600
Web, blog, Bikepics page
An optimist will tell you the glass is half full. The pessimist, half empty. The engineer will tell you the glass is twice the size it needs to be.

[carlnicholson...]

There is no emissions testing as yet as the bikes built to the EURO regs have not yet reached 3 years old to need a MOT.

It doesn't affect older bikes, just those built after the regs came in. IE mine in 2005. Bastard.
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"THOSE WHO RISK NOTHING, DO NOTHING, ACHIEVE NOTHING, BECOME NOTHING."

[stinkwheel]

[carlnicholson...]

MMM, the sweet taste of success, LAGER!

Given the chance, I would like to see how mine would go with some proper suspension and a 650 single. Probably not worth the effort, but would make for a fun ride me thinks!
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"THOSE WHO RISK NOTHING, DO NOTHING, ACHIEVE NOTHING, BECOME NOTHING."

[byke95]

Stink, if you ever want an all expenses paid vacation (well, there may be limits on booze consumption depending on how much you drink) to Bournemouth then just let me know.

Seriously, no catch!

small print: by accepting said offer I hereby agree to strip the front end of Phil's Z750 and stick the front end of a Z1000 on it.

[Itchy]

so in essence you've built a post 2002 KLE500? , as new KLEs use old GPZ500 engines don't they? ,

good job though , never dare do it meself only the basics

[carlnicholson...]

I'll post some pics or my engine when I get the film developed for comparison.
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"THOSE WHO RISK NOTHING, DO NOTHING, ACHIEVE NOTHING, BECOME NOTHING."