KTM 525 EXC as an Adventure Bike

Discussion in 'Thumpers' started by Karnage, Jan 31, 2007.

  1. Gumbydave

    Gumbydave motorcycle doofus

    Joined:
    Jan 4, 2006
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    why soitenly ........

    here it is almost finished, needs electrical box and carbon Fiber skin.
    there are two gen 5 osrams packed in there. Both come on high, one for low.......
    [​IMG]

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  2. moragabiker

    moragabiker Scott

    Joined:
    Apr 19, 2006
    Oddometer:
    47
    Location:
    On a dirt road
    Here's an update on how my 07 525 EXC is doing as an adventure tour bike -- We just completed another 2500 mile trip with the bike (photos are posted here http://eastbaydirtbag.smugmug.com/gallery/3475875#195625107 )

    The bike now has about 7000 miles on it. It is still the best adventure bike I've ever owned (especially in terms of fun and performance). Other than routine mainenance, I've experienced only two minor mechanical issues: (a) the front wheel bearings needed to be replaced at 5000 miles, and (b) the water pump seal began leaking at about 6000 miles. Otherwise, the bike has performed flawlessly!

    Cheers,

    Scott
  3. Stu

    Stu Buffo Maximus

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    Eastern YahooLand
    I want to see if anyone has more long-term results using the RFS as a long distance DS so I'm bringing the thread back to life.

    One very nice thing about the 525: if it starts to run ragged and gets hard to start you know the valves need adjusting (and possibly the plug). You can be in the middle of zilchistan and still adjust the RFS valves. Run the adjusting nut down until it just touches the valve stem (after finding TDC). Then just back it off 90 degrees and lock it down. It will be very, very close to .005" and you are good to go. You can't do that with shims unless you carry a pocket full of various sizes with you.

    The 525 Rawks!

    Stu
  4. jesusgatos

    jesusgatos fishing with dynamite

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    I didn't know that. Pretty cool.
  5. JKL

    JKL Rider

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    I believe it would be 60 degrees which is one point of the hex nut that holds the adjuster. It is .005" or .125mm gap due to the thread being .75 mm for one turn, so .75mm devided by 6 or (60 degrees) is .125mm.
  6. Broo C em

    Broo C em Been here awhile

    Joined:
    Jan 30, 2002
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    NP, Taranaki, NZ
    .. . such a great thread BUT now so quiet, apart from Moragabikers input some months ago, howsabout some ongoing user-reports from you guys out there racking up the iron-butt miles on ya 525's please.
    I just bought-in a tidy '05 & am keen to start modding it & some field-reports WOULD be great, especially if they're relevant to a couple of the significant questions from the thread that are still up-for-grabs, like whether or not ya REALLY need to fit a cush-drive rear wheel, or an HT oil cooler.
    An item that didnt get a heap of attention was whether or not to throw bucks at a steering damper for doolsport useage .. . ?
    Another is whether or not to fit some aftermarket speedo unit (with 14 exotic/bonus functions) or to just add a HardParts remote switch so as to be able to set elapsed distances on the fly (my new baby seems to need about 6 fingers on the speedo buttons to change/reset the modes etc).
    CIAO fer now
    BrooC in NZ
    "Angle Parked in a Parallel Uvinurse" :norton
  7. d0gWateR

    d0gWateR Goat Stuntaz DSMC

    Joined:
    Oct 25, 2003
    Oddometer:
    463
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    Chilliwack, BC CANADA
    Broo C em

    I have owned an 06 since new, now has about 7000kms or so, here's my observations so far. I modded everything, check my sig for link to thread where I covered it all. If the link isnt there when I'm done I'll edit this post and add the link.

    • Cush Drive - I don't run one, but I run knobbies and most of the time I'm in the dirt. No ransmission probs so far. No intention of fitting the cush drive.
    • HT Oil Cooler - I have one, no problems with engine or ignition, my buddy who doesn't use one has no problems at same mileage. Don't think it's necessary, but gives you the warm fuzzies knowing you have more oil down there.
    • Steering Damper - hmmm I have the GPR V2 with the integrated bar risers (you know the blingin orange one), its great but not necessary for dualsport in particular. It's great for offroading in general! If you like riding the streambeds and baby-heads - get one!
    • Trip computer - just buy the tripmaster switch for it. Found it very handy for TSD Rallies.
    Good luck!

    Edit: here's the linky to my 525 "Adventure" build thread
  8. Para504

    Para504 Spam, Spam, bacon & Spam!

    Joined:
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    +1 on the damper, at least in the technical riding (like above with the rocks and/or nasty roots). Also if you're riding in loose sand it can be helpful as well (as is leaning back & staying on the gas). Its not a cure all if you haven't adjusted / tuned your suspension correctly, but for the conditions above it does make a difference.
  9. Stu

    Stu Buffo Maximus

    Joined:
    Feb 4, 2004
    Oddometer:
    955
    Location:
    Eastern YahooLand
    Agree! One other place where it comes in handy is on tarmac in high cross winds. My 525 was really, really nervous at 70 MPH in these conditions, dangerously so, and the Motosportz damper calmed it right down. It also improved it in rocks. Worth it.

    Cush hub -- pretty expensive but if you put a lot of miles on hard surface I think it would be worth while. However, the SM boys run thousands of miles without them and are only on hard surface. I have one. I have changed out all the trashed needle bearings in transmissions (mainly on Maicos) I wish to.

    HT Oil Cooler -- if you run in a lot of heat or pull deep sand washes you will get your oil to the point of failure. The HT will prevent this. If you wish to run lighter oil (I run Rotella T synthetic 5W-40) you can do so with the cooler but are probably advised to run heavier oil without the cooler. The Rotella T helps me a lot in the colder weather I'm running now as well. If you want to run more miles between changes the HT will aid that. I have just short of 2 quarts now.

    Back on about page 10 or 12 I had a post on mounting Dirt Bagz to the sub frame. My mounts are still intact. I still only carry lighter stuff in the bagz. (I hope to get a T6 alloy sub frame made for it -- unchromed solid bar stock -- that will have tabs for mounting at the rear. More on that as it develops.)

    Stu
  10. reconsmr

    reconsmr Banned

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    1,522
    36,000 miles of all street on a 04 450 MXC motard conversion, valves adjusted twice, still runs like new. Just needed a CS seal/o ring and sprocket bolt, bulletproof otherwise. I'll check back when it crosses 40k,,,
  11. Sparrowhawk

    Sparrowhawk Long timer

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    Eastern Washington, USA
    I read through the thread on KTMTalk where you said the Laminar Lip stick-on windshield specified for the Duke II worked well for you on the 525 EXC. I was wonderin' if you had a picture showing it installed. I was also curious how you use it; leave it on all the time, stick it on for longer road days oly, or what. Since it has been over a year since you discussed it in that thread, do you have further thoughts??

    Thanks
  12. zer0t

    zer0t Adventurer

    Joined:
    Nov 17, 2007
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    54
    Location:
    Morris County, NJ
    Glad this post got bumped to the top. I am going to use my 530 as a light Adv bike more than a pure dirt bike. By the way a light adventure bike is really DS for me. A Sunday ride from North west NJ to Harriman NY on mostly back roads and at most 50 miles on a highway if I am in a hurry to get home. ;-)

    I need to go through all these posts now.

    Thanks,
    -z
  13. d0gWateR

    d0gWateR Goat Stuntaz DSMC

    Joined:
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    It seems every pic I have of the laminar lip, it's covered by my Wolfman carryall. Here's one from a Creel trip in 2006.

    [​IMG]

    It worked well enough, but with the wolfman bag covering it any "laminar" effect was gone. I smashed it to bits 2 days after this photo in a hard "unscheduled dismount".

    When it was mounted, it was very similar in height to a stock 640 adventure mask. I just through bolted it to the mask, the hook n loop that comes with it didn't work very well.

    I won't buy another one, because the windbreak gained is so little when used with the Wolfman Enduro Carryall. And I LOVE the Wolfman bag!! It rocks!!

    I'm waiting on brown santa (UPS) to bring me my next round of upgrades/changes/maintenance items.
    • Electrex 270W stator c/w Reg/Rect/Harness
    • Heated Grips
    • Baja Designs Diablo HID Headlight
    I already wired the bike for GPS and Electric vest, but adding the
    • heated grips
    • helmet cam
    • camcorder
    • satellite phone charger
    • blender (hey, I'm goin to Margaritaville)
    • bean grinder & coffemaker...
    OK, so the last two were a joke. But the stock stator puts out maybe 85W. I need to mod the stator to switch over to full DC for the HID headlight anyway, so I'm going with the Electrex ESG145 kit comes with everything ~$250

    I've also upgraded the battery to a Yuasa YZ7TS or whatever (search KTMTalk for battery upgrade).

    [​IMG]

    Waiting anxiously for this bad boy to show up.
  14. d0gWateR

    d0gWateR Goat Stuntaz DSMC

    Joined:
    Oct 25, 2003
    Oddometer:
    463
    Location:
    Chilliwack, BC CANADA
    I wanted to see Gumby Dave's pics he had posted but it looks like KTM Talk changed the IP of their pic server. I updated his post and here it is:


  15. d0gWateR

    d0gWateR Goat Stuntaz DSMC

    Joined:
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    Oddometer:
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    Chilliwack, BC CANADA
    Here's more of GumbyDave's headlight
    Nice! I'll take it!
  16. jgas

    jgas Stoogely Adventurerer

    Joined:
    Nov 7, 2006
    Oddometer:
    843
    I do it all on my 02 520. I've raced everything from MX, (outdoor, not SX), to National Enduros. Raced in local HS, and Enduros. It's managed grocery store duty, lots of dual sport/adventure, been used to make new single track as a pack mule, and been raced in GNCC. I don't keep a speedo hooked up so I don't know how many miles, and usually don't have an odometer, don't know how many miles, but I'd guess at least 25,000. This weekend it's going to carry me around Last Man Standing while I volunteer as a course official. The motor/trans has never been opened up, no major repairs.

    I've replaced countless wheel bearings and chain/sprockets. The only mods are a 15 oz heavier flywheel, KTM cooling fan, handlebar risers, better headlight and talilight, and a Guts seat.
  17. Cycletroll

    Cycletroll Catastrophe Specialist

    Joined:
    Apr 6, 2004
    Oddometer:
    1,083
    Location:
    Northern New Mexico
    Hey gang! Time to join a great thread:wink: I just bought a very clean '04 450EXC. It's set up nicely with a Scotts damper, a bunch of Enduro Engineering goodies and a skidplate. Only has 107hrs on it and they look to be mellow ones:clap It is not (yet) street legal.

    So, my question is: which DS kit? The Trick Dual Sport kits look well thought out. I'm just wondering, given that the bike already has a head and tail light, if there is a simpler way to set it up.

    Looking forward to reporting on many miles of fun on this bike!
  18. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

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    Crestwood, Kentucky
    I get my DS stuff from here http://www.procycle.us/main/dskit.htm You can pick and choose whatever parts you need. Nice guy with great prices and customer service.
  19. Sheep Shagger

    Sheep Shagger Show me your fleece

    Joined:
    Jul 30, 2007
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    Location:
    Where men are men and sheep get nervous
    http://www.cyclezonektm.com/
    It's made from KTM parts from EU bikes, since they are street legal, and use far nicer switches than the 07 & 08 KTM US models. It's all just plug-in and replacing old parts, the cleanest solution.

    Trick Dual Sport and Baja Designs etc all make nice kit's, but OEM KTM parts is the nicest in my opinion.
  20. Stu

    Stu Buffo Maximus

    Joined:
    Feb 4, 2004
    Oddometer:
    955
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    Eastern YahooLand
    I agree. The KTM parts make the best install and give the most reliable product. The LC4 switch gear plugged right into my 525 EXC wiring harness so I had more room on my handlebar and I had a way to shut the lights off. Cycle Zone can supply the parts and they are plug-n-play pretty much. The color of the wires may not match but the function is the same. Just note the differences so you can troubleshoot down the road when you have forgotten what you did.

    Stu