KTM 525 EXC as an Adventure Bike

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

  1. Rabbot

    Rabbot rain+superbike=adventure

    Joined:
    Jul 5, 2008
    Oddometer:
    563
    Location:
    Asheville NC
    I'd say that is about right. When I ride trails I average 24 MPH basic enduro speed. Most of the time I have the 17" SUMO setup. I ride forest service and twisty asphalt. Try to maintain 65 or so with some sprints to higher speeds thrown in for fun.
  2. The Bigfella

    The Bigfella Big Adventurer

    Joined:
    Apr 24, 2010
    Oddometer:
    2,543
    Location:
    One of the Burj's
    A few more....

    [​IMG]

    [​IMG]

    I like big barrels

    [​IMG]

    ... and dirty girls

    [​IMG]

    Hurried quietly across this one....

    [​IMG]

    It was wet, slippery and very, very narrow in places. 200' or more to the first stop going down...
  3. chippertheripper

    chippertheripper motorcycle junkie

    Joined:
    May 30, 2009
    Oddometer:
    2,813
    Location:
    s.e. mass
    butthole=puckered ^
  4. team ftb

    team ftb Befuddled Adventurer

    Joined:
    Mar 15, 2006
    Oddometer:
    1,772
    Location:
    Lost in the jungles of Thailand
    Good stuff Ian. Glad to see the rains making those boring fireroads interesting for ya:lol3.

    The guy in your picture of the ferry crossing is known for over charging, hope ya didn't get too screwed. How deep was the river crossing before this one ( short but lumpy solid rock bottom)?
  5. The Bigfella

    The Bigfella Big Adventurer

    Joined:
    Apr 24, 2010
    Oddometer:
    2,543
    Location:
    One of the Burj's
    Rivers haven't been too deep.... I've gotten through them.

    That lovely chap charged me 50,000 Kip.... but I wasn't going to wade it with the bike on my back... it was a tad fast flowing.
  6. RAZR

    RAZR I'll cut ya

    Joined:
    Feb 19, 2007
    Oddometer:
    9,592
    Location:
    Silver Lake (L.A.)
    WHOA:yikes
  7. selaznog

    selaznog Avoiding pavement

    Joined:
    Aug 11, 2007
    Oddometer:
    3,095
    Location:
    Rt 66 & The Rio Grande
    Installation report:

    *It was a little more than $40 to get the 55W upgrade.

    *The unit ships from China in about 7 days.

    *The bulb lacks a dimple to keep it in place, so I had to fashion a shim. No big deal.

    *The wiring harness is the same for a 1 or 2 bulb system, so there's some extra wiring to tidy up.

    *the sales guy didn't know his product. He thought it could be installed a la plug and play w/o wiring a lead and a ground. Wrong. Telephone tech guy answered quickly when I called to resolve the apparently conflicting info.

    *All in all a very easy install. Simple, unique connectors with no way to install incorrectly.

    *It's bright. WAY brighter than stock. Well worth $45.

    I haven't run it for long to make sure there are no overheating issues. I will do that Friday.
  8. yondering

    yondering Long timer

    Joined:
    Apr 6, 2009
    Oddometer:
    1,100
    Location:
    NW Wa. state
    selaznog, thanks for the report. I've been thinking about one of those. Debating whether to get the 35 or 55 W version. Seems like the 35 should be way brighter than my current 55W halogen, with less power draw. Haven't decided yet though.
  9. crazybrit

    crazybrit Long timer

    Joined:
    Mar 16, 2006
    Oddometer:
    8,556
    Location:
    Portland, OR
    I have the DDM dual hi-low version (slimline ballasts). Not sure if they still make it, I got it probably 18 months ago and have still not got around to installing it.
  10. yondering

    yondering Long timer

    Joined:
    Apr 6, 2009
    Oddometer:
    1,100
    Location:
    NW Wa. state
    Yeah, the hi-low version is what I was looking at too. It was still offered as of last week, anyway. Hurry up and install yours so you can tell me if I want one! :D

    Truth is, my stock '02 headlight with a 55/60W bulb works pretty well for my uses. I wouldn't mind a little more, but it's not bad as-is. I hear the light output of later models is a lot worse though.
  11. Beardoge

    Beardoge Been here awhile

    Joined:
    Aug 12, 2007
    Oddometer:
    380
    Location:
    By the twin bridges
    I was looking to purchase a 2004 525 EXC for $4200 with 1000 miles on it and it's exceptionally clean. Can some of you guys tell me if this is worth buying ? Any pitfalls or problems with this year bike ? It is registered with the Secretary of State and it's all street legal and ready to go so.... What say Ye ! Go or no Go.
  12. crazybrit

    crazybrit Long timer

    Joined:
    Mar 16, 2006
    Oddometer:
    8,556
    Location:
    Portland, OR
    I'll try and get to it once I get back from my trip. Still need to figure out the charging system issue :baldy My 2007 has the H4 55/60 also (square glass enclosure). Last long trip we swore we wouldn't ride at night but got caught out once and had to ride 20 miles of jeep trails in the dark. Light output isn't great, my buddies DRZ was much better. The 05/06 uses a 35/35w bulb.
  13. selaznog

    selaznog Avoiding pavement

    Joined:
    Aug 11, 2007
    Oddometer:
    3,095
    Location:
    Rt 66 & The Rio Grande
    The one I installed is the HI/LO. I also have a 2007 with the square headlight (I have heard the other headlights have melting problems with HIDs). The HI/LO does what it is supposed to do. You want one. :D

    I'm not worried about electrical output at this point. I have a TT stator and a lithium ion battery (not the light weight one with comparable power, but the big, overkill, I-refuse-to-kick-this-damn-bike-again one). I also replaced my brake light with a LED bulb, so more power saving there. We'll see what happens with the lights, but with the stock light it would never tame a trickle charge because it was always fully charged, even after sitting for a couple of weeks.
  14. crazybrit

    crazybrit Long timer

    Joined:
    Mar 16, 2006
    Oddometer:
    8,556
    Location:
    Portland, OR
    I assume you are also running the TT regulator? It and the Lithium Ion batteries are supposedly not a great combo. Trailtech told me that they are not compatible with the Shorai. And for the Turntech Lithium, from the horses mouth: http://www.thumpertalk.com/topic/81...ement/page__st__40__p__10104600#entry10104600. Probably good you got the one with lots of capacity and have the HID :D Talking to Joe, if you have a lot of accessory draw, it sounds like it can be borderline.
  15. bhorocks

    bhorocks Been here awhile

    Joined:
    Jun 30, 2008
    Oddometer:
    346
    Location:
    Phoenix az

    sounds like a lot of money for an 04... I just paid 2500 for an 05. yeah it has 110 hours 3000 miles but still....

    better have alot of aftermarket.
  16. crash n bern

    crash n bern Long timer

    Joined:
    Mar 5, 2007
    Oddometer:
    1,328
    Location:
    Brisbane Oztrailia
  17. sonic reducer

    sonic reducer Been here awhile

    Joined:
    Aug 19, 2007
    Oddometer:
    257
    Location:
    Seattle WA
    I just picked up an '03 525exc to fix my lack of a thumper. It's plated already and seems in good condition although I have not rode it yet due to a busted radiator. however it starts up 2nd kick from cold.

    I am going to change the oil(rotella t6), replace the radiator, bleed the brakes, check every bolt on the bike, and check the valves. what are some of the common issues should check? I already found out about the water pump seal thing and I do not believe the weep hole is weeping yet.

    who is running on the street with no cush drive? can anyone give empirical evidence that this is a bad idea? the threads I read on this subject seemed to have a lot of arguing with little actual evidence to back up.

    what coolant is everyone running? some say engine ice, but I'd prefer to run some kind of water based coolant in case of a leak out in the boonies to be able to top it with water. plus I'm in western wa not death valley although I will ride central wa a good amount I hope.
  18. selaznog

    selaznog Avoiding pavement

    Joined:
    Aug 11, 2007
    Oddometer:
    3,095
    Location:
    Rt 66 & The Rio Grande
    I am running the TT regulator with a Turn Tech battery. Joe makes a great product, but I think he is mistaken about conflict between a TT system and a lithium ion battery. My charging system has worked flawlessly for two years.

    Prior to the time I bought the battery I had been having jetting issues (don't even get me started there!). The bike didn't start right away, the battery would die and I would start kicking. So, I then bought a TT stator and regulator kit. That didn't solve the problem, because no matter how much charge was going in when the bike was running, getting the bike to run in the first place was too much for the battery. I solved the jetting issue, (props to JD Jetting) but as anyone with a stock-sized battery on a KTM thumper knows, pressing the E-start on a cold bike is an exercise in divine faith...you can literally hear the battery drain with each press of the button, and you pray this won't be one of those times you have to kick. Enter the Turn Tech battery.

    Rather than order off the web, I called Turn Tech, and told them my woes, told them I had a TT stator and regulator, and asked for the most powerful battery I could fit in the space. They were more circumspect about whether there was a conflict. They said it was a maybe. I was willing to try anything, so I ordered a battery at $199. They shipped it to me, and in two years it has worked great with a stock (except for a LED tail light bulb) lighting set up.

    Proof is in the pudding as they say, and here is where IMHO the proof lays. Turn Tech recommends that you do not use a trickle charger regularly, and in fact I spoke with Turn Tech about this. They said it is fine to use one the night before a ride if the bike has been sitting, but not beyond that. In two years I have attached the trickle charger many times, only to see that the bike was already fully charged. I even wondered if I was getting an error reading from the charger, so leaving it plugged in I turned on the lights to get a power draw and a different reading from the charger. No error; the bike was fully charged. If Joe were right about the conflict (remember, he says the lithium battery needs a slightly higher voltage charge, and the TT system runs lower, thus failing to charge the battery), then a bigger battery would have more room to charge when placed on a charger, and yet my battery consistently has no room to charge.

    I also don't notice a difference when riding different styles. I live in the desert but also ride mountains often. On my particular trails/roads, the power draw is much higher in the desert due to fan and lugging on tighter trails, whereas I tend to get a heavy wrist on the more flowing forest/jeep roads in the mountains. Either way, the bike stays charged.

    Who knows, maybe I got lucky. but you couldn't get me to give up my TT system + Turn Tech battery. :thumb
  19. crazybrit

    crazybrit Long timer

    Joined:
    Mar 16, 2006
    Oddometer:
    8,556
    Location:
    Portland, OR
    Well, like I said, if you ask Trailtech they'll tell you their system isn't compatible with a Shorai (same battery chemistry). However when I tested a Trailtech on a 530 last week it was outputting 14.5V into the battery. Neither of the new regulators I have will output more than 13.6V which was Joe's experience also. When I mentioned the 14.5V test reading to the R&D engineer at Trailtech he told me that was over spec even though the owner of the bike had never touched the epoxy sealed adjustment pot and like you had been happy with charging for last 2 years. I believe yours works for you. Since I'm having issues getting the system working on my bike I decided to not complicate things further and just stick with their recommendation of Lead Acid. The Turntech looks like a great product and Joe is indeed a great guy!!
  20. yondering

    yondering Long timer

    Joined:
    Apr 6, 2009
    Oddometer:
    1,100
    Location:
    NW Wa. state
    I haven't figured out why my '02 has such good light output, more than the later models, but it's much better than my buddies DRZ. Maybe a different reflector? Only thing I've changed is to add heavier gauge wire to the headlight circuit; maybe that's the difference. The stock wiring is pretty small.