KTM 525 EXC as an Adventure Bike

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

  1. falcn

    falcn Squidless Soul

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    I did my own DC harness with a relay tied to the ignition, etc. made a fuse block, put relates in for the headlight high and low beam. Didn't like the way the DS kit did it.
  2. MadM

    MadM Dreamer

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    On a 2003 I rescently worked on, it was a 27mm.
    ---------------------------------------------------------------------------------

    So I have done a lot of reading those last few days and here is what I could gather, regarding carb setup and this should be the best overall setup.

    MJ 162 (or should I go with bigger one like 172 for more top end?)
    PJ 42
    OCEMP needle #4 clip
    Honda AC pump diaphram (#16021-MEB-771)
    AC Puump setup as per AC101 sticky thread on KTMTalk
    O-ring mod

    My riding area is Central Europe, on the edge of Alps. Riding from 2000-4000ft most of the time, but simetimes I go higher up to 6000 or down to sea level, temps range 15-35 degress Celsius. Riding is DS/Rally/HardEnduro. Basically I would like to set the carb up as best as I can.

    Would this kind of carb setup be good? I am going on a vacation with my LC8 and would like to order parts before I leave, to minimise down time when I get back.

    I apprichiate any input on this matter.

    P.S.: I really hope @RideFreak would give an opinion on this, since he helped me out a lot on my 300 2t a while back.
  3. longtallsally

    longtallsally Yeah I'm a chick

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    Yep, that's how I did it on my '05 (minus the fuse block, which I probably should have done, but I relayed and fused everything) that had a DS kit. The '07 is factory plated and lighted (?) so for all intents and purposes I'm just replacing he tail light. The D.C. Stator just behaves differently and since there is either 3 feet of snow on the ground or surface of the sun hot here, I've ridden very little so I couldn't remember how it was to behave. I do recall something in the Ricky Stator instructions talking about energizing at different time and such, but just couldn't remember.

    The only thing left is that I have a mix of LED and incandescent turn signals so I have the fast flash. I'll probably put LEDs on the front too, but I really could care less as this bike is barely ever on the street. The plate is just to connect trails.
  4. GR0NK

    GR0NK Got some screws loose!

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    Check the fuel screw o-ring too. They flatten out or get hard/break after a while and cause all sorts of problems like you describe.


    Sean :brow
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  5. The Letter J

    The Letter J Long timer

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    If most of your riding will be on pavement, I'd skip the CRF pump diaphragm. The shorter squirt duration of the Honda part is noticeably beneficial in the dirt where you can break traction and spool up the engine quickly... but onroad, where traction is at/near 100%, your engine rpm does not rise as quickly and the longer squirt duration of the stock KTM AP feels noticeably smoother to me. YMMV.
  6. bpowa

    bpowa Been here awhile

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    no way of telling until you remove the carb and inspect.. The easiest thing to do is to remove your jets; pilot and main. Clean it and put it back in. If that dont work, the carb should be torn down.. Alot of times irregular rpm is due to the throttle slide plate gasket. Dont use brake clean it will tear the seals.
  7. MadM

    MadM Dreamer

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    Anyone has a KTM part number for OCEMP needle? or HONDA/Yamaha? Those are the dealers around me for moto stuff. I can't order from states.
  8. falcn

    falcn Squidless Soul

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    I will have to look up where I got mine.
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  9. falcn

    falcn Squidless Soul

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    Turns out I just found it on Ebay and ordered one. Keihin-FCR was the seller. I don't think I still have the bag that might have had the part number.

    You can also order from Jets-R-Us I believe:
    All needles for FCR 35-41mm carbs:
    https://www.jetsrus.com/a_jets_by_carburetor_type/needle_keihin_N427-OC_FCR_35-41mm.html

    OC-EMP Page
    https://www.jetsrus.com/individual_parts/017_264_su.html

    I have ordered lots of parts (even for my Elefant Mikuni carbs) from Jets R Us - good company in my experience.
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  10. MadM

    MadM Dreamer

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    Thanks for the info! I had to go with ebay too. At the moment I am waiting on the needle, honda diaphragm and some fresh jets from ktm, oh and a spark plug ;-)
  11. falcn

    falcn Squidless Soul

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    Haven't tried the Honda Diaphragm....hmm.
  12. Wrycque

    Wrycque Enthusiast

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    I know this goes back a bit but I was surprised to learn that the Safari tank for my 2005 560SMR actually holds 4.3 gallons. (Same as 450EXC) Got it from justgastanks.com
  13. Wrycque

    Wrycque Enthusiast

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    The problem I found when I had the MXC tank and seat on my bike was that I tend to ride way up front on the seat. That combination makes it literally a ball buster for me. The shape of the seat is too steep in the front - it hurt me badly a couple of times every time I rode it. Any large tank that uses the stock seat is much better in this regard.
  14. RENCRN8

    RENCRN8 Been here awhile

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    Weird. My stock seat pan with seat concepts foam works with my MXC tank lovely and is very comfortable. FB_IMG_1498061051541.jpg
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  15. Wrycque

    Wrycque Enthusiast

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    I think you'd find the proper MXC Seat that goes with that MXC tank is steeper in the front area. I never tried the EXC seat on mine like you are using.
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  16. filterwrench

    filterwrench Been here awhile

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    The Safari tank on my 525 holds 15.3 liters. 3 Georgie Lake d.jpg
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  17. MadM

    MadM Dreamer

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    Since I don't have all carb parts yet, I decided to only do o-ring mod before next ride.

    I have never seen such a clean pulley space on a used bike before.
    [​IMG]

    O-ring installed.
    [​IMG]

    Hopefully this is the way it is supposed to run or should I use 2 of them? Size is roughly ID 5/16 with OD 7/16, I am in a metric area ;-)
  18. bpowa

    bpowa Been here awhile

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    Can you tell me how it feels with 18mm vs 20mm?

    Update.. I took it for a 5 minute spin on the street. Im not sure if I would leave it on. The front feels too heavy for me. It dont feel as flikable as the stock, but the front feels eally planted.. Its almost the same feeling as having my SM wheels on. Almost like having a damper cranked up twords the top. really likes to center itself
    It maybe good for mx but i like the more tight technical stuff on dirt.
  19. cjbiker

    cjbiker Nobody's Robot

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    Are you talking about the 14mm or 20mm triples?
  20. bpowa

    bpowa Been here awhile

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    yes.. I switched my dirt wheels from sm 17's. I decided to see how it felt with 14mm tiple with dirt wheels.