KTM 525 EXC as an Adventure Bike

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

  1. yondering

    yondering Long timer

    Joined:
    Apr 6, 2009
    Oddometer:
    1,100
    Location:
    NW Wa. state
    I have the Motion Pro tool also, except it cost half that much and is in a red box, got it from RockyMountainatv.

    My experience is that a link swaged with the Motion Pro tool is harder to remove than the KTM version; meaning the link is swaged in place at least as good, or better than, OEM. It's relatively easy to use, just don't go so far that the link binds up.
  2. dave186

    dave186 Been here awhile

    Joined:
    May 27, 2012
    Oddometer:
    253
    Location:
    Idaho
    That grey gasket maker will do the job, and I have used it myself but this stuff is better.


    [​IMG]

    You should be able to find it at any auto parts store, the permatex version looks just like it and has a similar part number.

    The advantage of the anaerobic sealant is it doesnt plug up your oil passages.
  3. RideFreak

    RideFreak Torque Junkie

    Joined:
    Apr 17, 2009
    Oddometer:
    8,598
    Location:
    Out in the NM Dez somewhere
    When you grind off the flared ends of the old cc masterlink, grind into the plate a bit, that will remove most of the interference and allow it to be removed w/o a tool. All you'll need is a small punch to drive the plate off the pins. It's actually pretty easy. When it comes to restaking the new link comon sense prevails, don't crank it down super tight, it's not needed. I've seen guys put cutup strips of .003 feeler guage between the plate and the links it's pressing down on to provide clearance when staking, I've always just crimped them (slowly) removing the tool a couple times to check the progress and to ensure it wasn't binding the chain.
  4. espressodrinker

    espressodrinker Cape Town Wanderer

    Joined:
    Mar 31, 2008
    Oddometer:
    208
    How do you stop the bits of grinding dust from going into the engine?
  5. GR0NK

    GR0NK Got some screws loose!

    Joined:
    Sep 24, 2006
    Oddometer:
    4,013
    Location:
    Stuck in 80s
    I use a dremel with a cut-off disc. It already minimizes the amount of dust but I stuff a big rag around the cam gear to catch whatever does come off.


    Sean :bmwrider
  6. selaznog

    selaznog Avoiding pavement

    Joined:
    Aug 11, 2007
    Oddometer:
    3,341
    Location:
    Rt 66 & The Rio Grande
    Is anyone running the Acerbis 6.6 tank on a 2004 525 exc? I'm selling mine, and a potential buyer is trying to see if it will work on his 2004. The Just Gas Tanks site says it will work on a 2005 SX. I had always thought they fit all the rfs bikes. Anyway, thoughts from a 2004 owner would be appreciated.
  7. GR0NK

    GR0NK Got some screws loose!

    Joined:
    Sep 24, 2006
    Oddometer:
    4,013
    Location:
    Stuck in 80s
    The tanks are interchangeable on RFS models 2000 to 2007.



    Sean :bmwrider
  8. espressodrinker

    espressodrinker Cape Town Wanderer

    Joined:
    Mar 31, 2008
    Oddometer:
    208
    It fits fine on my '06 525 EXC.
  9. SHOREBILL

    SHOREBILL Some Guy

    Joined:
    Dec 9, 2006
    Oddometer:
    383
    Location:
    Lakewood, CO
    I do not know if this applies to an 04, but the xc and sx came with a different seat (more pronouced angle at the nose) which will not mate up with the 6.6 acebris. It will barely mate to 3.5? gal acebris. Any stock xcw exc seat will work.

    Live well.
    Bill
  10. MKJ

    MKJ Married w/ Children

    Joined:
    Sep 18, 2011
    Oddometer:
    727
    Location:
    Upland, CA
    Has anyone done any head upgrades to their 525? I just did, and replace the top end. Strong, but popping and snorting. Jetting issues, possibly?
  11. theGrinch

    theGrinch SNF Dream Riders

    Joined:
    Jan 16, 2011
    Oddometer:
    2,296
    Location:
    On the move
    What upgrades did you do to the head?

    .
  12. MKJ

    MKJ Married w/ Children

    Joined:
    Sep 18, 2011
    Oddometer:
    727
    Location:
    Upland, CA
    1mm over sized intake valves, relieved and polish chamber to unshroud valves.
  13. yondering

    yondering Long timer

    Joined:
    Apr 6, 2009
    Oddometer:
    1,100
    Location:
    NW Wa. state
    Did you do the head work yourself, and if so, did you make the mistake of polishing the intake tract? That can cause what you describe.
  14. yondering

    yondering Long timer

    Joined:
    Apr 6, 2009
    Oddometer:
    1,100
    Location:
    NW Wa. state
    Woohoo, just took my 520 EXC out for a test ride after being down all winter. It now has a 540 12.5:1 kit and 8/33 cam. It's a noticeable improvement over stock; the power is still smooth with no hit, but it feels like the whole power band jumped up a gear. Before it would pull power wheelies in 4th easily, now it does the same in 5th. :clap
  15. MKJ

    MKJ Married w/ Children

    Joined:
    Sep 18, 2011
    Oddometer:
    727
    Location:
    Upland, CA
    No
  16. GR0NK

    GR0NK Got some screws loose!

    Joined:
    Sep 24, 2006
    Oddometer:
    4,013
    Location:
    Stuck in 80s
    Be kind to that motor, that was my favorite combo but I abused it and paid the price.
    That 8/33 cam is all mid and top. On loose dirt/gravel you'll blow right to the limiter if you hold it, even in 6th.
    Carry a can of octane booster. They didn't have super at that little gas station in the middle of nowhere or you just don't trust the gas? Dump it in the tank. If you run that 12.3:1 motor (12.5:1 but you unshrouded the valves) WOT on bad gas, this happens.

    [​IMG]

    Combustion chamber ran too hot, valve seat came out, piston hit the valve...at 8000RPM...repeatedly.


    As for the popping, lean out the fuel mixture. I think I went down one or two on the main. I know it sounds counterintuitive but the bigger piston creates a bigger vaccum signal so the stock jetting is too fat.

    Enjoy it.:freaky



    Sean :bmwrider
  17. clapped_r6

    clapped_r6 The Spoad Warrior

    Joined:
    Jan 3, 2006
    Oddometer:
    3,134
    Location:
    Ridgefield, WA
    2 rfs and a dr650 do moab for the first time.
    bump this thread up!

    <iframe frameborder="0" scrolling="no" width="640" height="360" src="http://api.smugmug.com/services/embed/2455671351_k8nFdw8?width=640&height=360&albumId=27723866&albumKey=BcFcj4"></iframe>
  18. crazybrit

    crazybrit Long timer

    Joined:
    Mar 16, 2006
    Oddometer:
    8,570
    Location:
    Portland, OR
    Nice video, shame about the hair :D
  19. clapped_r6

    clapped_r6 The Spoad Warrior

    Joined:
    Jan 3, 2006
    Oddometer:
    3,134
    Location:
    Ridgefield, WA
    it was my mo-mo-mohawk.

    and the term you're searching for is "majestic"
  20. crazybrit

    crazybrit Long timer

    Joined:
    Mar 16, 2006
    Oddometer:
    8,570
    Location:
    Portland, OR
    The King of Vantucky :lol3