KTM 525 EXC as an Adventure Bike

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

  1. longtallsally

    longtallsally Yeah I'm a chick

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    Nah the spacers are gone too- it appears I literally have just the tank. The spacers are really the only thing I was worried about as I thought the bolt would be pretty easy to get at a decent hardware store, as well as the bars.

    I figure I can do some measurements, and/or make a simple template to do the bends as it just looks like 2 (and even on the site you provided, he had to bend a little) and I'd need to get the angles correct.

    Putting a guard or smaller petcock seems to be an issue as well. I like to fall down, so keeping it safe is a priority.

    I'm going to try Acerbis USA today and see if I get lucky, or maybe some suggestions.
  2. longtallsally

    longtallsally Yeah I'm a chick

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    Called Acerbis and they had the bolt! :clap They are putting it in the mail today. :thumb

    The gentleman I talked to said the bars were as easy as I thought and the spacers can be easily replaced with washers. Cool! I'll post up what I end up with if anyone is interested.
  3. crazybrit

    crazybrit Long timer

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    The flat spacer could be but the above doesn't seem a great solution for the cupped one that covers the captive nut on the frame.

    I've never felt it necessary to make a petcock guard but as I said, I use a smaller petcock on the lhs.
  4. longtallsally

    longtallsally Yeah I'm a chick

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    I see now what you mean:

    [​IMG]

    Hmmm... Suggestions? I agree in that I don't like the thought of just putting a couple washers on top of the welded nut on the frame with those fingers exposed. The old McMaster Carr might have something as well, but I'm I'm not sure.

    Something that just came to mind is that I could use a socket that is laying around for the spacer. I would probably have to bore out the ratchet side to allow clearance of the bolt through, but that might be a simple solution depending on the depth needed.
  5. crazybrit

    crazybrit Long timer

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    If you're going to go to the trouble of boring out a ratchet, just have someone make you one on a lathe. Simple job, maybe post in your regional forum, I bet you'll find someone who can make one for a case of beer. If you need the dimensions PM me and I can send them to you.
  6. RideFreak

    RideFreak Torque Junkie

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    Getting someone to make them up on a lathe is the best option but if you don't have any luck there you can make up 2 collars easy enough out of a piece of 1" steel tubing, tack a couple washers to the pieces of pipe and you're good. Going into a machine shop cold will probably cost ya, anytime I get something made it's a min of $40, sort of expensive for those.
  7. oregonlmd

    oregonlmd Dirt,street,its all good.

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    I'm not suggesting you NOT use them, and I always ran them on mine, but I know some have not installed the support bars and have not had an issue with not using them.
  8. RAZR

    RAZR I'll cut ya

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    longtallsally.... if you can wait until DVDAZE, you can inspect my 6.6 tank. :deal
  9. longtallsally

    longtallsally Yeah I'm a chick

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    Thanks! That's probably the next time I'll want it and hope to have it mounted then, but I'd like to see a "correct" mount.

    The suggestion of taking some tube and welding a washer to it sounds good as well- I figured I could easily redneck inganere something, and that sounds like a really good idea. Another one might be to just find a pipe cap that is pretty close and drill a hole for the bolt. I'll go snoop around and see what I find.

    Thanks for all the help, guys.
  10. RAZR

    RAZR I'll cut ya

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    I can text you pics of my tank accessories. hit me up.
  11. relayda

    relayda Been here awhile

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    Anyone know if there is a writeup on changing the crank nut on an RFS?
    Thanks
  12. RideFreak

    RideFreak Torque Junkie

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    Here's what I sent Gunslinger;

    Dave Hopkins (aka DJH) on KTMTalk sells the nuts, his email is: davehopkins@windermere.com
    He prefers email for contacting him.

    Anyway the stock nut is alum, what happens is the primary gear on the crank pushes against the nut slightly, just enough to slightly deform the alum and make a small amount of play. It's a reverse thread so it doesn't come all the way off, at least I've never heard of that happening but the gear is now slightly loose on the crankshaft which causes it to move against the woodruff key deforming it slightly also. The end result is a noisy bottom end. The RFS is noisy anyway, esp with an alum skid plate but it's even worse when this occurs. After seeing the alum nut used I'd recommend this mod to anyone with an RFS, the alum nut is junk IMO and should be replaced even if it isn't loose. You'll need to buy the sidecover gasket, woodruff key and steel nut. The parts will run about $35. I ordered the woodruff key and tusk sidecover gasket from Rocky Mtn ATV who sells OEM parts and has $7.00 shipping on small orders. I got the nut from Dave Hopkins, it's about $6.00 plus shipping. Torque is 93 ft lbs, (I went 100 since it's steel now)

    The job is easy, you pull the kickstarter, brake pedal and clutch cover, remove the primary nut (reverse thread) using a penny between the primary gear and clutch to hold it, then take off 6 allen bolts on the balancer located just behind the primary nut, gently work the balancer off, replace the woodruff using locktight in the groove. Reinstall the balancer and 6 allens, replace the nut with the steel unit, torque then install the cover back on. let it sit for 24 hrs before starting it.
  13. relayda

    relayda Been here awhile

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    Thanks Chris!
  14. blackness

    blackness more riding

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  15. Moto Vaquero

    Moto Vaquero Trail less traveled

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  16. longtallsally

    longtallsally Yeah I'm a chick

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    I got motarded this weekend... :deal

    [​IMG]

    As if I wasn't already in total lust with this silly little machine...
  17. crazybrit

    crazybrit Long timer

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    Wow that looks fantastic ..... i need to keep my eyes open for a used set for my 07 450.

    I bet it's a blast in the tight stuff.
  18. longtallsally

    longtallsally Yeah I'm a chick

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    Hated it.... :evil

    Wheels came with the bike along with the Exxon Valdez tank I was asking about. I finished the valves and oil (speaking of which, I've not a clue how you can do it with the left radiator still hooked up) and thought I'd give them a try.

    The PO said he'd not used them much, so the tires are pretty old and initially I planned on selling them. Um, ain't gonna happen now. Only a couple slides, and based on the age of the tires (and that the sun was going down) I didn't get too nuts, but wow. I'd forgotten what sticky street tires gripped like. Yum.
  19. crazybrit

    crazybrit Long timer

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    You can do the exhaust after loosening the radiators but yes it's a challenge. No need to drain the rads. Gets easier with practice :D I'm still trying to perfect the 1/6th turn method rather than using the MP feelers. First few times I was way off after I verified (after) with a feeler.

    If you change your mind [or if anyone else knows of a well priced setup] ping me, I've got some spare cash right now.
  20. clapped_r6

    clapped_r6 The Spoad Warrior

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    what capacity is that tank? my friend has that same tank, and he wasn't sure.