KTM 525 EXC as an Adventure Bike

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

  1. crazybrit

    crazybrit Long timer

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    Has anyone had a problem getting these to work together.

    I've had the oil cooler on the bike for a while. Just bought the Trailtech stator.

    Unfortunately it wasn't working. Idling I can measure 13.4v at the battery but it drops to 12.6 with low beam and 12.4 with hi-beam. Lower if I short the fan on.

    Trailtech tech support said this wasn't normal. After debugging on the phone it turned out that there was a short in the stator. Measuring between each yellow wire and ground it was ~150M ohms when cold but would drop to about 1M ohms when warm. They said there should only be open circuit.

    They sent me a replacement but the (lack of) charging symptoms are identical. I'm baffled. I get 1M ohm short to ground on both yellow outputs when warm but I'm not seeing anything when it's cold (open circuit).

    I carefully checked that no part of the stator windings is contacting the HT-racing cover. The only part that is making contact (as I can see where it has rubbed) is the metal cable strain relief on the underside of the stator (it's plastic on the OEM) but this is mounted to the center/ground part of the stator which in turn is grounded to the case via the 2 mounting bolts.

    Anyone had similar problems? I left a message w/ Bill Sr at HTR. I expect TT (for debugging) will want me to rip off the HTR setup and go back to stock. Otherwise I might truck the bike up there since they're only 20 miles away.
  2. selaznog

    selaznog Avoiding pavement

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    My HT cooler and TT stator have worked fine. I've never kicked since adding the stator, and the few times I've put the bike on a tender it's already charged.

    Removing the cooler to test the difference is the only way to tell if it's part of the problem. If the results are the same, then you know it's not a cooler/stator conflict. If they are different, then at least you have narrowed your problem. It wouldn't take long and I'm sure the vendors will appreciate your attempt at self help.
  3. selaznog

    selaznog Avoiding pavement

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    I rarely ride at night, but recently I found myself in the desert with a stock headlight that was next to worthless. What aftermarket headlight alternatives have you guys tried, and what do you think about the value (cost vs. improvement) of the product? I don't see myself going top shelf for a HID light on this bike. :ear
  4. RAZR

    RAZR I'll cut ya

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    i have the Trail Tech X2 HID and i do like it.

    BUT,

    a friend that just aquired a Husaberg (AKA Blue KTM) and bought and installed a HID light that some guy on ADV is making that looks identical to stock with a little more glass sticking out for the HID light to fit.

    i can get more info on this from him, but he's out of town riding. i'll post up when i hear from him.:deal

    but where i'm getting at with this is, him and i went night riding and he was behind me and his light made my Trail Tech X2 look like it was the stock KTM headlight.:eek1 i think he paid $120 and it comes with the headlight cowl unit as one.
  5. DRjoe

    DRjoe Long timer

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    Did it have high and low beam.
  6. crazybrit

    crazybrit Long timer

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    I'm curious what voltages people are getting at idle, idle+low beam and idle+high beam (measured at the battery terminals) with the Trailtech stator and voltage regulator.

    Anyone feel inclined to help me out?

    Yeah. I may have to go the self-help route :D

    Since I get open (correct) when cold and 1M ohm (apparently bad) when warm I was thinking I might see if I can reproduce this outside of the bike first.

    Not sure what is the best way to heat up the stator. Leave out in sun, immerse in plastic tub of warm oil ?

    If that doesn't reproduce it, I'll have to try removing the HT and re-installing the stock cover.
  7. hizzo3

    hizzo3 Adventurer

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    So i skimmed through about 30 pages of the almost 300 pages on this thread... aside from asking where my award is, here is what I gather from the 5XX bike as an adventure bike:

    I am looking at the 2013 500 exc as an adventure conversion. I have a dl1000 but want something more fun off road to not only allow me to better my off road skills but tossing around a 550 lbs dirt bike not fun, if you want to consider a dl1000 on loose gravel, sand and open fields. I want to be able to ideally do things like cdr, big bend and the like without trailering.

    Pro
    light & nimble (cant justify a 350 for such little weight difference @ 6'1 230 lbs)
    powerful
    aside from trials riding, it can do just about everything else with right set up

    Con
    questionable rear subframe, needs robust racks if toting gear
    small oil capacity, short oil change interval (fix with oil cooler) Ideally want closer to 2k miles minimum interval
    not so comfortable on long rides (if i am doing an IBA ride, i have my strom)
    headlight is crap and would need a total replacement as 40% of my riding is at night, in deer country


    Other notes
    valves need to be checked every 30 hrs, but experience shows that 6-12k seems like a realistic interval
    needs a cush type rear hub for pavement
    possible regear for highway and carry spare sprockets for dirt

    Is there anything I am missing if I were to go pick one of these up and abuse it?
  8. LukasM

    LukasM Long timer

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    Sounds like the setup from Paul aka PW_Garfield, it uses a KTM ATV lense that fits into the stock 09+ headlight shroud. Haven't tried it but I like the other stuff that Paul makes.


    Alternatively if you go the $$s, the Baja Designs Squadron LED with a dimmer is a bad ass setup with tons of light, very durable, light and compact. No ballasts and bulbs to fail, which is a common problem with some HID lights.
  9. DRjoe

    DRjoe Long timer

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    How does dimming the led compare to a propper low beam?
  10. LukasM

    LukasM Long timer

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    I don't have a dimmer yet, but my guess is at least as well as the stock light, but not as well as a proper HID projector with cut-off. So if you are riding mostly on public roads it's probably not the best option. For mostly off road with occasional road use it's awesome though.

    I believe that Justin now has one on his 525/570, and there are lots of guys in the Vendors thread?

  11. tHEtREV

    tHEtREV Captain Awesome

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    You got me slightly worried now.

    I have a TT stator on the way, and I was just about to order a HT cooler...

    On a side note, I have a 6.6g Acerbis tank on the way, my 525 has a 540 kit and full FMF Ti exhaust, is there any other big money items I should look at getting for it?

    The bike is an 03 and will probably just sit around looking pretty until I can drag it out to some desert tracks every few months.

    I just want to get the big stuff out the way first and then work on getting the $200 and under items later.

    And what ever money I don't spend on the 525 now, gets thrown at my 640...
  12. chippertheripper

    chippertheripper motorcycle junkie

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    Hizzy: the new subframes are more substantial than the rfs generation. I still don't think theyre BMW-gs worthy, but certainly better.
    You can extend the life of the oil road riding...those recommendations are for dirtbikes.
    The jury is still out on the Cush drive hub, for me. I ride my bike like an idiot (it's a race bike) and have yet to see the kind of wear pictured a few pages ago. Tread even lighter, that spline will last that much longer.
  13. B-Rod

    B-Rod RubberNecker

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    From the seat of my pants, riding like an idiot is smoother. Lugging along makes it really feel like it's really hammering.
  14. chippertheripper

    chippertheripper motorcycle junkie

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    Ahhh, yup b. I was referring to my 560 (race supermoto) and the cs issue, specifically. It's about to get streeted, which is why I lurk in this thread a bunch.
    But you're 100% right. Faster is generally smoother...excepting the sudden separation of man and motorbike.
  15. clapped_r6

    clapped_r6 The Spoad Warrior

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    me too. i'm going to let crazybrit do all the heavy lifting, and then benefit from his experience. i was planning on that same stator / cooler combo.
  16. crazybrit

    crazybrit Long timer

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    it isn't looking great
  17. clapped_r6

    clapped_r6 The Spoad Warrior

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    well i haven't read anything in the past about interference problems, so i'm leaning towards blaming the mechanic :deal
  18. RAZR

    RAZR I'll cut ya

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    yes, that is it. i still haven't heard from my buddy, but some of you (and of course you LukasM, know of my buddy i'm talking about... Lost Rider)

    his light is BRIGHT!!!



    another friend has that LED Squadron light set up. and yes, it's bright, but not as bright as HID.... AND the light beam is not that great. there is no spot light, it's just bright and shoots light out everywhere. not great for street riding and off road it shoots too much off to the sides.
  19. mookymoo

    mookymoo Mookish Mook

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    I have the HT cooler & TT stator & no problems (not done loads of hours on it though).
    I'd happily test for you - but bike and I are on different continents...

    light off to the sides is good if you have to worry about hitting animals...
    I have the X2 HID - its good - but I still don't have lots of confidence to wick it up on windy bush tracks at night because the road verges are still a bit shadowed...
  20. hizzo3

    hizzo3 Adventurer

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    How far are y'all extending oil changes with the HT oil cooler? Any issues with rocks coming up and hitting it?

    Sent from my Galaxy Nexus using Tapatalk 2