2005 ktm 400 exc

Discussion in 'Thumpers' started by Silverbird, May 10, 2013.

  1. Silverbird

    Silverbird Been here awhile

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    I am looking at an 05 400 EXC. I've read good things about this bike. Anyone have any wisdom to share?
    #1
  2. LukasM

    LukasM Long timer

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    Solid bike and engine, discussed in every little detail you could want to know in the 8 years it has been out.

    Do a search here (use google with your search term and site:advrider.com) and look through the "RFS" subforum on KTMtalk.
    #2
  3. Rusty Rocket

    Rusty Rocket Life behind "Bars"

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    Love mine. It is the same bike as the 450/525 with a shorter stroke engine. It revs quicker and is supposed to turn better because of the short stroke. (I don't understand that idea well) The only thing I had trouble with was overheating. It boils easy with stock jetting. I put in JD jet kit and that helped, but not enough. I went to a higher pressure radiator cap and that helped, but still not enough. I was about to add a fan kit when I tried Evans Coolant. It has a 300+ degree boil point. Hasn't over heated in 10 months. (since day 1 on Evans)

    http://www.ktm-parts.com/mm5/mercha...gclid=CNj3nZD9i7cCFQua4Aod8DwAJg#.UY0i90qSPcw

    It's not cheap, but I went through more Engine Ice dollarwise than this in the first year.. one bottle is enough with some to spare. I went back to the lower pressure rad cap to save the water pump seals.

    RFS motors are the best KTM 4T engine ever made. I have 8000 + miles on mine and it still runs fantastic.

    I weigh 200 without gear on and for the rocks and roots of New England, I have .47 fork springs and an 8.0 rear spring. That solved suspension for me. YMMV..

    with 2006 shroud graphics:
    [​IMG]
    #3
  4. Silverbird

    Silverbird Been here awhile

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    Thanks for your input, I brought her home yesterday.
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  5. Rusty Rocket

    Rusty Rocket Life behind "Bars"

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    :clap:freaky
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  6. Off the grid

    Off the grid Unsmooth Operator

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    That buzzing in your earhole, NorCal.

    Well done, you will love it. :freaky
    #6
  7. Possu

    Possu de-nOObed!

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    Took my old 2004 400EXC to about 400 hours / 10,000 miles on the original crank, clutch & piston. Very reliable, easy to service, can do the valves without a feeler gauge and there's still excellent aftermarket support.
    #7
  8. Silverbird

    Silverbird Been here awhile

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    Thanks everyone. Let me know if there is something I just cant live without doing to her (tips/tricks/mods).
    #8
  9. Silverbird

    Silverbird Been here awhile

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    Well you were right. I boiled her over 4 time first time out. I am starting to do a few mods to help this problem. Any advise on how to drain the coolant? After years of working on Jap bikes it's like learning a new language.
    #9
  10. go2cnavy

    go2cnavy Dont Worry Be Brappy

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    Don't pay more than $1800 for one when you can score a 450 for just a little more.
    #10
  11. clapped_r6

    clapped_r6 The Spoad Warrior

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    http://www.advrider.com/forums/showthread.php?t=373580

    coolant drain is right above the exhaust pipe? or right around there somewhere.

    keep in mind the coolant level is not supposed to be all the way to the top. if you overfill, it will spit up.
    #11
  12. clapped_r6

    clapped_r6 The Spoad Warrior

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    did you not see he got the bike more than 3 weeks ago?
    and some people actually prefer the 400. i know, hard to believe, right?

    thank you for your extremely helpful and timely info!
    #12
  13. OhioPT

    OhioPT Adventure Wannabe

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    What's the jetting (needle type/position, pilot and main jets)? They are setup terribly lean from the factory. Get a radiator fan too. Try Evans or Engine ice if those 2 things don't help. Also, shut the bike off if you are sitting idle for a while- that's a big one ;)
    #13
  14. Off the grid

    Off the grid Unsmooth Operator

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    Coolant plug is the bottom of the rad. You can also remove the thermostat to drain it.

    What you need, in order:
    JD jet kit
    KTM hard parts fan
    Engine Ice

    This will solve your boiling over problem.
    #14
  15. Silverbird

    Silverbird Been here awhile

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    Yeah that's the direction I'm headed. I live in a pretty warm climate so I may delete the T-stat and put on some silicone hoses as well.
    #15
  16. Off the grid

    Off the grid Unsmooth Operator

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    Not needed, but your call. KTM OEM stuff is pretty high-grade. :thumb
    #16
  17. go2cnavy

    go2cnavy Dont Worry Be Brappy

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    :stfu Slow your roll keyboard commando... I don't know what he paid for it. It's a great bike, but old. Not worth more than $2K IMO - and he asked for opinions.

    Folks have mentioned jetting, coolant, etc... what's your riding style? These bikes will boil if you're riding too slow. With my 450, I installed a Trail Tech Vapor and set the high and danger temps. When I get to the high limit, an orange light comes on and tells me to pick up the pace a little to increase air flow. Danger, red, tells me to haul ass to get more air flow.

    Do you have radiator guards that might be blocking air flow? How are the fins on your radiators?
    #17
  18. clapped_r6

    clapped_r6 The Spoad Warrior

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    grid knows of what he speaks. jd jetting and the fan works wonders. there's a lot of good info at ktmtalk about different needles and doing it up yourself. i don't know about that, my bike already had the jd kit and it runs perfect. fyi idling for extended periods is not suggested!

    probably won't buy you much, but it does make the coolant path simpler. codyy has some good pics of his setup, search for that (it's a deleted bypass hose / rad nipple capped off)

    when you posted your extremely accurate market analysis of ktm's on the east coast, he had already purchased the bike. what were you hoping to accomplish with that? i believe the tone of his original post was "what do you think about this bike", not "how much do you think it's worth?"

    but, thanks anyways!
    #18
  19. Off the grid

    Off the grid Unsmooth Operator

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    Thanks mate, it's all from experience, ie I've done the same stupid sht. :lol3

    The JD jet kit had by far the biggest impact on how cool my EXC ran. I still boiled over with Engine Ice, rad fan and higher bar radiator cap. (forgot to add that to my list)

    Fixed. :thumb
    #19
  20. LukasM

    LukasM Long timer

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    Just came back from 4 days of off-roading in the Romanian mountains with my 450 RFS. Mostly slow going on wet, muddy and tight single track in first and second gear, some long full throttle uphills. Ambient temps around 25°C.

    Bike didn't boil over once, which I attribute to the 1.8 bar radiator cap and the fairly rich JD kit. I did get a leak in one of the radiator hoses which stopped after I re-tightened the hose clamps.

    Since I already have a DC conversion I am probably going to install a fan kit anyway, but this will only help at crawlingly slow speeds when you have no air flow through the radiators.
    #20