KTM 525 EXC as an Adventure Bike

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

  1. thirsty 1

    thirsty 1 Rider Supporter

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    Now that you say it I think it is a BD tank. Better pic for reference. I had to lower it about a half inch to get the rack on with it. image.jpg
    krautman and cmbthumper like this.
  2. skibum69

    skibum69 slave to gravity Super Supporter

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    Derek at MotoLabs will sell you all the proper sized hex heads to replace all of your JIS screws.
    Whodatschrome likes this.
  3. Whodatschrome

    Whodatschrome Long timer

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    I also have one of those Baja Designs rear tanks for my 525 as well. I bought it used, and I still have yet to mount it up. The BD tank is definitely different from that Ebay KTM tank.
  4. thirsty 1

    thirsty 1 Rider Supporter

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    @Whodatschrome yeah, A nice bit of insurance on long outings. I generally put a little in it, run it out, and continue on. Works well enough!
  5. 99' xr650L

    99' xr650L dual sport guy

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    Did a 2017-2021 mask (w/ Cyclops Ultra bulb) and fender conversion.

    [​IMG]
  6. Uncle-roby

    Uncle-roby Been here awhile

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    I've just bought a 2003 EXC450 with 2000 kilometers on the clock and for the moment I am very happy about it.
    Miles for gallon, or better (I live in Italy) kilometers for liters are incredibly good: between 22 and 26 km/l.
    I use it as dual sport: leave home towards the mountain, ride mountains roads and rocky military roads and back.

    It is a wheely machine! :)
    Mike Dirt, Wattner, shinyribs and 2 others like this.
  7. tHEtREV

    tHEtREV Encouragement award recipient. tEAM iDIOT.

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    thirsty 1 likes this.
  8. skibum69

    skibum69 slave to gravity Super Supporter

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    Where did I hear about sub tanks being available today?
  9. cmbthumper

    cmbthumper Long timer Supporter

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    Very nice. I was going to do mine as well but the PO left me a present in the 2 rear bolts broken off at the fender. I now have to finger out how to extract them but at least I have 1/4" of stud to work with.
    99' xr650L likes this.
  10. portero72

    portero72 Been here awhile

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    austin, tx, y'all
    I have the Cyclops bulb in my 07 mask and fender. Was the newer mask an improvement in light or was it just done for the sake of hawtness?
  11. TroopThrowback

    TroopThrowback Been here awhile

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    Alright it already showed up! Looks like a good fit. Need to source the longer bolts required but everything lines up.

    How did you plumb fuel lines?

    IMG_8439.jpg
    IMG_8440.jpg
    Whodatschrome and thirsty 1 like this.
  12. thirsty 1

    thirsty 1 Rider Supporter

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  13. cmbthumper

    cmbthumper Long timer Supporter

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    Suspension came back and installed.

    While i was waiting for the suspension i installed a new counter shaft seal, o-ring and bushing but still leaks. I ran the bike for a few seconds without the sprocket and Dirt Tricks washer on if that has anything to do with it. I will have to do some research on why it leaks. Maybe it was the Tusk CS kit or me. Done quit a few on other bikes and never had one leak brand new. I only used one of the correct size o-rings and not sure why they put 2 of the same one in the kit.

    20210822_134916.jpg
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  14. Ned1

    Ned1 Do you rent that thing out as a speedbump?

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    2 suggestions.... 1) get the o-ring for the 300, it's slightly thicker. 2) if your oil is even a little bit overfilled it will find its way out the c/s seal. spent a lot of time dealing with this and it was always always always too much oil.

    had to laugh when my kid went throught it after getting the engine (formerly my engine and bike) back from rebuild, reassembling, and it pissed oil right off the bat. being 18 and knowing everything there is to know in the world he wouldn't believe a word I said. then I goaded him into dropping the oil and measuring what came out. guess what... overfilled by 250ml :jack

    hope you solve on it, it's damned annoying.
  15. Grreatdog

    Grreatdog Long timer Supporter

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    The rectangular mask with a Cyclops bulb worked really well on my old MXC 200. I honestly don't know if my 08 mask is an upgrade or not.

    Mainly because I can't remember what the upper cut off looked like on my old 200. But my 08 mask has a really good upper cut off. It would easily pass inspection.
  16. cmbthumper

    cmbthumper Long timer Supporter

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    Thank you for the info. I did notice when i took out whatever o-ring was in there that it was just a hair thicker than the tusk one. Not sure if it was OEM or not. The Seal itself was different MFG than the Tusk s who really knows. What year do i look for on the 300?

    I am super OCD on my oil changes so i can say maybe a 5ml overfill but no way anything over that.
  17. Ned1

    Ned1 Do you rent that thing out as a speedbump?

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    @cmbthumper the 07 will do it. it's 2.0mm vs 1.78.

    O-RING 25,00X2,00 NBR 70
    Part# 0770250020

    O-RING 25,12X1,78 NBR70
    Part# 0770020220

    i'm assuming you're measuring your oil in a cup before you fill. smart move. word to the wise, and you probably know this already but put an even liter into the bike if you don't do filters. if you're doing filters it's 1.2 liters and no more. and lift the front end of the bike up when you're draining it to get all the oil out. it's tempting to top it up because the sight glass shows it low but the sight glass lies. i'm sure it's all old news to you and anyone here but these rfs engines do better with less oil in them than more.

    hth.
    Jman209, Grreatdog and cmbthumper like this.
  18. Renardracer

    Renardracer Adventurer

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    Ho guyz

    Some photos of the TET section 4 i did in august.
    The bike ran great, no issue, no complain, nothing. She is now at 18.000kms, and runs as a young lady IMG_20210810_095114.jpg

    IMG_20210809_121126.jpg

    IMG_20210805_072536.jpg

    And just to notice how my skid plate saved my engine one or both IMG_20210731_174419.jpg

    IMG_20210731_174410.jpg
    Ned1, z_rider, husqvarna and 7 others like this.
  19. cmbthumper

    cmbthumper Long timer Supporter

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    Ned1,
    Thank you for the Oring tip. Installed the 300 oring and a ktm oem sleeve bushing and no leaky leaky.

    Graphics installed and ready for next weekend suspension test.

    20210829_112053.jpg 20210829_112040.jpg
    krautman, z_rider, Ned1 and 7 others like this.
  20. Northwoods Snowman

    Northwoods Snowman Been here awhile

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    Nevermind, I figured it out.