KTM 525 EXC as an Adventure Bike

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

  1. Grreatdog

    Grreatdog Long timer

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    I sold a plated MXC200 when I bought my 525. So, obviously, I like it just fine on gnarly single track even if it isn't quite as fast as the 200 there.

    But I am an (almost) old man who has been doing this a very long time that likes being able to loaf through hard stuff on the massive low end power.

    I am probably not as fast on the 525 as that 200. After all, the 525 does require some throttle discretion. But the 525 is way less tiring for me.

    It is just a different riding style. The 200 demanded concentration and craved full on attack riding. The 525 just doesn't demand as much energy to go fast.
    enduro16, VTwinner and Big Toe like this.
  2. woodsxr

    woodsxr Been here awhile

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    My bike seems a little twitchy in single track and I had planned on looking into this after I finished a couple projects.
    I know you can buy different offset triple clamps to help with this.
    My bike has a aftermarket billet clamp set and I think they are 18MM. Not sure what would be optimum
  3. bpowa

    bpowa Been here awhile

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    My SM triple is 14mm the origional is 20mm.. Imma give it a try this weekend when I put the dirt wheels on. Hopefully it would be more nimble. It takes a lot of effort for me on this bike.. When I got it I researched weight and it was only about 20lbs heavier than the 250x. I figured it cant be that much different.
    Brtp4 likes this.
  4. Brtp4

    Brtp4 Powdercoat it.

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    I put 18s on mine and the difference is noticeably better. Have 14s but have not tried. Looking forward too your thoughts.

    BP
    VTwinner likes this.
  5. Baja Ho

    Baja Ho Been here awhile

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    Central Coast, CA. USA & Cabo San Lucas, Baja Sur
    Nice pic's and great that you are riding with your Honey.

    falcn likes this.
  6. 10K

    10K Trail Runner

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    Are you at the Verde river?
  7. mikey413

    mikey413 Adventurer

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    At the Verde just east of the Perkinsville bridge
  8. Moto Beak

    Moto Beak Professional Amateur

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    Arvada, CO
    I've spent this summer getting used to an '06 525EXC, coming off of a 2 stroke 380MXC . I've owned an '05 450EXC and an '05 CRF450X in the past and didn't like them. I've spent a lot of time on an '09 WR250F as well. I generally prefer 2 strokes 300cc or bigger, for the easy torque. I'm a half-throttle kind of guy. With all that considered, I'm in love with the 525. Like Grreatdog said, it doesn't take much energy. I didn't like it for singletrack at first, but the more I relaxed on the bike the better it worked. I've surprised some fast guys on smaller bikes by keeping up or pulling away on the real technical trails. She's a big girl and does take some extra finesse in the tight stuff, but just ride a gear higher than you might normally and the power is more friendly. There's no getting past the physics of the 525, and your CRF would feel like a trials bike in comparison. Just relax and give it some time.
  9. falcn

    falcn Squidless Soul

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    Sagecreek rim road - I added no music. )


    I have more, but probably boring to other people.

    Jimmy the Heater likes this.
  10. longtallsally

    longtallsally Yeah I'm a chick

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    Escaped from Kalifornistan
    I have an exceptionally dippy question to ask. I've been carrying my trail tools on the rear fender for some time. I'm getting tired of eating the license plate, so I've moved the tools to a fanny pack. And am now for the 4th time rebuilding the tail section.

    As I'm doing it, I thought it was a simple ground, running, and brake light setup. This is an '07 so all lights from the factory. The only thing I've changed is a Ricky Stator and obviously a few different tai lights.

    Anyway, the last light was totally destroyed and I've got no reference as to what goes where.

    [​IMG]

    No worry- or so I thought- I'll just do the meter dance and find ground, and running (IGN on) and process of elimination gives me brakes. WRONG! I get tone for 2 of the wires as ground and no juice on anything.

    Bust out the manual and look for what goes where. Uh, I've read a lot of wiring diagrams and I've got a wire going to the brake switch(es). The other 2 go to what I'm assuming is a flasher (it's not labelled in the diagram- it's a box with a circle with an x in it and the ones next to it just like it are labelled right and left front flasher). They then go over to the dimmer/passing switch?

    Did I miss a meeting or is my rudimentary undersatanding of 12v electrics more simple than I thought?
  11. bryantjt

    bryantjt Long timer

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    Flashers probably have /had a single ground wire with a double plug on the end. Left and right flashers are usually colored, orange and blue for positive I've seen several times.

    Tail will have ground, running, and brake. Ground is likely solid black, one of the others would likely be white and black, and then whatever is left is it for your wires.

    You could always take a spare bulb and touch it to the wires as you try different buttons too.
  12. Grreatdog

    Grreatdog Long timer

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    On a KTM grounds are usually brown and hots usually white. But, I don't believe that is a stock KTM tail light.

    The wiring is heavier gauge than KTM uses and the wrong colors. Plus the light and inner fender are the wrong shape.

    My guess is the wiring was spliced somewhere and that was probably an aftermarket inner fender and tail light.

    The correct KTM inner fender and light are maybe $75 new. For a couple of dollars more Baja Designs sells an LED light mounted on the correct KTM inner fender.

    https://www.bajadesigns.com/products/taillight-04-07-ktm-euro-led-fender.asp
  13. longtallsally

    longtallsally Yeah I'm a chick

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    Thanks. Well, in theory it should be as simple as ground, running, and brake lights. And that means I should get 12v for running if I turn the ignition on and put put the meter to ground and the running lamp. Nope. I did the last 2 lights in there, and they worked perfect, so I'm not concerned with a botched up job. Aside from right there at the back, the harness is untouched and the turn signals work perfectly (I've already wired the new ones in).

    OK, so I go to a continuity test to check for ground. 2 of the 3 terminals give me a beep (continuity). That tells me I have a short- or so I thought. I trace the harness and can't find a break- thus my confusion.

    The only thing I can think is that there is something "interesting" that goes on with the all DC stator. The headlight stays on for a period of time after I shut the bike down since I did that conversion, and it doesn't come on unless the bike is running.

    I just finished an oil change and valve check, so I guess I'll put the tank back on and fire it and see if that changes anything, but otherwise I'm stumped.

    In terms of wiring once again it should be easy peasy:

    Light (just a cheeseball Tusk RMATV LED):
    - Yellow (ground)
    - Black (running)
    - Red (brake)

    Bike (based on the wiring diagram):
    - Green/White (front and rear brake switches)
    - Brown (into what I'm assuming is that flasher deal)
    - White (also into that flasher deal, but splits off to the headlight dimmer switch)

    So this tells me I'd do:
    - Brake: Red (light side) to Green/White (bike side)
    - Ground: Yellow (light side) to Brown (bike side)
    - Running: Black (light side) to White (bike side)

    Again, I guess put the tank on and fire it and see if the bike needs to be running to energize everything. This only strange as my '05 RFS got juice to the tail light with IGN on. But that was a Baja Designs wiring setup in that, so not a fair comparison.
  14. MadM

    MadM Dreamer

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    Slovenia
    Guys, I need to pick your brains about a slight problem I have with my 06 450. When I was out on a ride a few days ago the bike had some funny symptoms:
    - hard to idle at the beginning of the ride
    - irregular idle rpm (from too low to run to so high it actually pulled nicely in first gear)
    - down low bog when opening the throttle fast
    - missing some power, compared to other RFS in the group

    From about a 1/4 throttle on it ran nicely, just lacked in power from what it should be on a 450, it is really tame. But up to 1/4 throttle it was barely ride-able.

    I am in for a carb rebuild?
  15. Bowber

    Bowber Been here awhile

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    Kirkby Stephen, Cumbria, UK
    Trailtech rr, dc conversion. The rr turns a feed on from the battery once it gets a feed from the stator. The tail wiring is just normal tail feed stop light feed and earth, earth is brown, I think the tail is white, the other is the brake light.

    Steve
  16. Beta450

    Beta450 Been here awhile

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    The symptoms sounds like a plugged pilot jet and or bad gas.
    falcn and MadM like this.
  17. MadM

    MadM Dreamer

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    Thanks, will look into it during my vacation in the next 2 weeks. At least I will have something to read about while I am off work :)
  18. longtallsally

    longtallsally Yeah I'm a chick

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    Escaped from Kalifornistan
    Just a quick update: yep, the bike has to be running. My wiring connections were correct above. All is well...
    falcn likes this.
  19. Guoseph

    Guoseph Been here awhile

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    Sep 8, 2011
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    Alameda, California
    Anyone know what size socket I need to remove the clutch basket? I've read 27mm and 30mm. I'd rather have bought the correct one before taking the bike apart.
  20. bobfab

    bobfab Long timer

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    May 11, 2009
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    Westminster CO
    I just did a shifter shaft replacement on a 02 400mxc and I think it was just a snap ring on the clutch basket and shaft


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