KTM 525 EXC as an Adventure Bike

[Indy Unlimited]

Thick O-Ring

Originally Posted by blake716

Okay, I had that bass ackwards.

I'm goint to install the kit when I get off of work today.

What about the accelerator pump o-ring.....should I use the thick or thin o-ring?

[blake716]

Originally Posted by Indy Unlimited

Thick O-Ring

Thanks.
I set everything up just like the directions said, but I haven't tried it out yet. My air filter was torn. Not sure how that happened.
I have to go to the KTM shop tomorrow to pick up a new air filter and a few more parts, then I'll see how it runs.

[blake716]

I got to ride my bike some today since I re-jetted it. When I turn the throttle real quick, it bogs a little. Even died a couple of times.
I can roll the throttle on a little slower and it comes to life. When the bike is moving and I stab at the throttle and it's pretty crisp.

What should I adjust?

It's set up exactly like the instructions said:
Red needle, 5th clip down, stock pilot, and 170 main.
I put the large o-ring on the accelerator pump, and put the spacer on the diaphragm.


On a side note, my tank came in today. Holy hell, that thing is HUGE.





Here it is from another angle.

[Tusker]

Blake,
I have the 6.6 gal tank, too, and it's really not that big when you get it on the bike. One thing that helps is that it's thin between your legs when standing, so it feels pretty normal.

I noticed in the picture that your chain looks extremely tight. You need to run it quite loose on these bikes or you will run into countershaft problems. Many guys take the shock out and adjust the chain by running the rear wheel through all it's travel to make sure you don't have a tight spot.

[blake716]

Originally Posted by Tusker

I noticed in the picture that your chain looks extremely tight. You need to run it quite loose on these bikes or you will run into countershaft problems. Many guys take the shock out and adjust the chain by running the rear wheel through all it's travel to make sure you don't have a tight spot.

I adjusted it yesterday.

You even had me second guessing myself. It does look really tight in that picture. Maybe the angle...

I just went out in the garage and checked it.



When I first got the bike, I had to pull the shock off to remove the head pipe.
When I did that, I jacked up the swingarm where it was pointing right at the countershaft and adjusted it with 10mm of slack.
After I put the shock back on, I took the bike off of the stand and put 2 marks on my wrench so I'd know how much slack to leave
without having to remove the shock when it was time to adjust the chain again.

Good observation though. I have new sprockets and a chain ordered too, just in case you notice the piss poor condition my rear sprocket is in.

[socaltrailrider]

Originally Posted by blake716

I got to ride my bike some today since I re-jetted it. When I turn the throttle real quick, it bogs a little. Even died a couple of times.
I can roll the throttle on a little slower and it comes to life. When the bike is moving and I stab at the throttle and it's pretty crisp.

What should I adjust?

It's set up exactly like the instructions said:
Red needle, 5th clip down, stock pilot, and 170 main.
I put the large o-ring on the accelerator pump, and put the spacer on the diaphragm.


On a side note, my tank came in today. Holy hell, that thing is HUGE.





Here it is from another angle.

I had the same problem on my 525. Shoot JD an e-mail and he will give you an adjustment. It's been awhile and i can't remember what he told me, but it did work. I'll see if I can dig up the e-mail.

[Indy Unlimited]

You need to adjust the timing and duration of the AC Pump"

Here is what works and it is easy to explain:

http://www.thumperfaq.com/mxa_ap.htm

Originally Posted by blake716

I got to ride my bike some today since I re-jetted it. When I turn the throttle real quick, it bogs a little. Even died a couple of times.
I can roll the throttle on a little slower and it comes to life. When the bike is moving and I stab at the throttle and it's pretty crisp.

What should I adjust?

It's set up exactly like the instructions said:
Red needle, 5th clip down, stock pilot, and 170 main.
I put the large o-ring on the accelerator pump, and put the spacer on the diaphragm.

[blake716]

Originally Posted by Indy Unlimited

You need to adjust the timing and duration of the AC Pump"

Here is what works and it is easy to explain:

http://www.thumperfaq.com/mxa_ap.htm

Lots of good info there. Thanks.

[clapped_r6]

wth?

on my 07 there appears to be a decompression lever on the head. no cable attached, no provisions for it on the clutch.

vestigial? or does this actually have some use?

[crazybrit]

Originally Posted by clapped_r6

wth?

on my 07 there appears to be a decompression lever on the head. no cable attached, no provisions for it on the clutch.

vestigial? or does this actually have some use?

You don't really need it (it's not an LC4). You have the Brembo clutch. It's master cyl lacks the mount point for the decomp. For some reason they switched from Magura to Brembo for the 2007. Fiche is wrong, it still shows Magura slave on engine page. Handlebar controls page is correct, shows Brembo. Just remember you *must* use Brake Fluid. If you insist you can install the brembo hot start master cyl cover (oem or hardparts) and hot start lever (pm me if you want part#s) or loop a long zip tie through the connection on the side of the motor.

I put a Magura on my 07 as the Brembo had way more pull effort compared to my old 05 (even with one of the shorter cLever levers). Now have some minor slippage when pulling away in 1st in soft stuff, not sure what's going on. I measured the push rod and it's same as the (incorrect) engine fiche page.

[Jackazz]

Originally Posted by crazybrit

You don't really need it (it's not an LC4). You have the Brembo clutch. It's master cyl lacks the mount point for the decomp. For some reason they switched from Magura to Brembo for the 2007. Fiche is wrong.

My 07 RFS I've had since new has the magura clutch master with a single perch so maybe that was changed to brembo mid year like the locking lever I found out about the hard way (check yours, its a 10$ part that's easy to get to).
The 2007 has the internal auto decompression that's always worked flawlessly for me but some guys have used a zip tye on the engine lever to help clear it out, Maybe they crash a lot or ride in a bunch of water?

[The Bigfella]

The 525's been surging a bit lately... someone suggested that the front sprocket might be hooked. Doesn't look bad enough to cause that though, does it?

[blake716]

^^^ Looks fine to me. Barely starting to break in.

[The Bigfella]

Originally Posted by blake716

^^^ Looks fine to me. Barely starting to break in.

Excellent. Thanks mate.

[Indy Unlimited]

looks fine for a belt drive!