KTM 525 EXC as an Adventure Bike

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

  1. team ftb

    team ftb Befuddled Adventurer

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    +2 I had my solenoid shit the bed after 485 hours.
  2. team ftb

    team ftb Befuddled Adventurer

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  3. selaznog

    selaznog Avoiding pavement

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    How exactly would I be able to tell if it's the solenoid?
  4. bryantjt

    bryantjt Long timer

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    Jumper around it. Use a heavy wire, 12 gauge or better and touch it to the starter stud and the battery positive terminal. This will tell you if the starter itself is good.

    If the starter is good you now know there is either a problem with the start button or the solenoid.

    The start button can be checked with the continuity function on a multimeter. Find the 2 wires for it behind the headlight and plug your lead into the connector and try the button. If the meter beeps or gives a reading (depending on type of meter) then the button is good.

    Then you can take your meter and flip to dc voltage and touch one lead to the positive lead on the solenoid (probably in your airbox) and the other to battery negative or chassis ground.

    If that shows battery voltage that wire is good.

    Then connect to ground (or battery) and connect to the lead leaving the solenoid that goes to the starter and watch the meter when you try the start button. You should see battery voltage and the starter should work if all is good.

    If not it could be one of 2 fuses on the solenoid or a bad connection between start button and solenoid. You can check for voltage at the solenoid connectors when pressing the start button.


    I went through all of the above and found no voltage out from the solenoid when hitting the start button so I bought a new one and that made no difference. Following my wire diagram in the owners manual I found that most everything is grounded in the bolt at the coil. This bolt was loose in my case. I cleaned the connection and tightened the bolt and all is well.
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  5. bryantjt

    bryantjt Long timer

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    I had to remove the tank to get to the coil.

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  6. clapped_r6

    clapped_r6 The Spoad Warrior

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    is anyone running a different offset for the triples?

    i know the geometry changed for 08, (my 200 steered off the front a whole lot better)

    what are options, besides a frame swap? i remember reading about some different triples, but can't seem to find it now.

    tia
  7. team ftb

    team ftb Befuddled Adventurer

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    I used 17 degree offset Topars and steered a bit better.
  8. LukasM

    LukasM Long timer

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    What are you trying to achieve, better stability or better turning?
  9. clapped_r6

    clapped_r6 The Spoad Warrior

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    better turning. i have proper springs for my weight, i run the chain in the longer wheelbase configuration, and i just can't trust the front. it feels like it wants to wash out if i'm not on the gas.

    i know the newer (08) chassis was supposed to be way better in this regard, just looking to see if anyone has made the RFS turn a bit better like the newer stuff. (used to have an 08 200 xc-w that steered off the front extremely well, which i know is apples and oranges comparison , but have read stuff about the 08 XC4 chassis being similar?)

    as a d/s bike it works great, fast on trails it's a bit vague. i see that there's a variety of different offset triples, however i don't exactly understand the differences and what they do.

    don't want to reinvent the wheel!
  10. selaznog

    selaznog Avoiding pavement

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    Thank you.

    One of the fuses by the solenoid was blown. I now have a starter. BUT, the headlight, tail light and brake light do not work. Is there a separate fuse somewhere? Other likely cause? It doesn't seem likely the headlight switch is bad, as the rear lights do not work, and the same switch works the turn signals and horn, which both work. :dunno

    Edit: the headlight and rear lights do not work when the engine is running.
  11. bryantjt

    bryantjt Long timer

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    Mine being an 06 had to have a Baja Designs ds kit installed for lighting so I have a separate harness and fuse for lights. I would start with the wiring diagram in the manual and back track through grounds and fuses.

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  12. RideFreak

    RideFreak Torque Junkie

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    Pretty sure the HL/TL on the exe are run off A/C Steve, that's going to have a seperate input directly from the stator wires, different from the TS & Horn which are D/C and run off the batt. Not sure about a fuse in the circuit though, Akasy just had his apart, he could probably tell ya.
  13. MKJ

    MKJ Married w/ Children

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    Did you check all the fuses inside the side cover behind the air box? that is where your starter fuse should be.
  14. selaznog

    selaznog Avoiding pavement

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    I only saw two 10A fuses. Are there more?
  15. selaznog

    selaznog Avoiding pavement

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    Again, I don't know crap about electrics, but...

    If the HL/TL worked without the motor running (before this mess started), then wouldn't they not be powered by a separate stator input but instead by a battery?

    Also, I have a TrailTech stator, so isn't everything DC now?

    This is the problem with a factory street legal bike. If I had needed to install all this electrical stuff myself, then I'd know what everything was. :rofl
  16. bryantjt

    bryantjt Long timer

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    Yes, if they worked before with the motor off they are on a circuit that is battery powered. Could also be that whatever blew the fuse popped the same bulbs.

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  17. RideFreak

    RideFreak Torque Junkie

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    Yup, the TT system converts everything over to DC. sounds like a fuse or a connection. Did you check that little bracket behind the headlight that holds all the connectors? One of those might have come loose.
  18. selaznog

    selaznog Avoiding pavement

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    Bulbs, as in light bulbs? I actually had a HID system installed when things stopped working, but I have disconnected it and have a known good bulb plugged in so that I minimize complexity while troubleshooting.

    So the weird thing is that when I lost the starter I still had lights for at least a while.

    Chris, yes, I looked behind the light but didn't see anything obvious. I sprayed the entire area with compressed air and fiddled with all the connections that are visible. I think it's time to trace wires with the diagram. :bluduh. I'll take the bike to sipapu either way. There shouldn't be a shortage of knowledgeable people willing to speculate over a beer.
  19. DRjoe

    DRjoe Long timer

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    I have a slightly modified 520exc and I fitted the 16mm (I think) offset triple clamps to it.
    I was amazed at the difference in the front end.
    It just grips and turns in so much better.

    In theory less offset = more trail which should make the bike way more stable and a lot harder to turn in tight but in reality I got the best of both worlds with increased stability and the ability to actually turn in tight without the front end going by by.

    The steering is heavier but on the plus side I don't have to use the damper as much anymore.
  20. Gunslinger1

    Gunslinger1 GIVE'R

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