Abuse-proofing a 525

[Ocean1]

So the pile of orange crap loosely gathered into a motorcycle shape I bought a month ago is now behaving like a 525 should. I think. Mostly.

The header isn't long for this world so I'll sort out an aftermarket zorst system for it soon. I'm on the lookout for a slightly larger tank and may do a bit of seat surgery, (although I believe the 13L tank need a different seat anyway).

In the meantime I want to fit an oil cooler, hopefully one that's not too likely to get skewered by some stray twig and bleed the poor old dear to death. I've used frame components as coolers before now but in this case I think it's be a bit tricky.

Does anyone know if there's an EXC-specific cooler / kit available? Or where I can lay my hands on one like the DR800s use?

Cheers in advance.

[slowpoke]

Check out this site: http://www.dsadventures.com/525reviews.htm

You'll never look at an over priced XR650R again.

[Taz]

Ok. The standard seat will fit with the 13 litre tank you just gotta get rough with it. I recommend fitting a coolant overflow bottle I used this one (http://www.rlrproducts.com/images/CRT_kit_ebay.jpg).

I don't believe the bike needs an oil cooler in our climate but if you must the best one would be one of these (http://www.blaisracingservices.com/ktm/ktm-4-stroke-parts/ktm-motor/drive-line/01-07-ktm-400/450/525-exc/mxc/xc-oil-cooler/prod_233.html).

15-45 Gearing will do it all. 14-45 if the going is tight. 14-48 for trail riding.

Add a bash plate if it hasn't already got one and away you go.

Taz.

[Ocean1]

Check out this site: http://www.dsadventures.com/525reviews.htm

You'll never look at an over priced XR650R again.

Ta, some good stuff there.


Ok. The standard seat will fit with the 13 litre tank you just gotta get rough with it. I recommend fitting a coolant overflow bottle I used this
Good to know, cheers. Let me know if you see a tank for sale eh?

I don't believe the bike needs an oil cooler in our climate but if you must the best one would be one of these (http://www.blaisracingservices.com/ktm/ktm-4-stroke-parts/ktm-motor/drive-line/01-07-ktm-400/450/525-exc/mxc/xc-oil-cooler/prod_233.html).
Looks like a good solution, will check cost.

15-45 Gearing will do it all. 14-45 if the going is tight. 14-48 for trail riding.
Add a bash plate if it hasn't already got one and away you go.
Taz.
Gearing is currently 15/45, got no problems with it, especially with 6 gears and a nice clutch.
Found an OE plastic bash plate on EBay, arrived with perfect timing yesterday. Bloody nice bit of kit.

[Taz]

I've got the 13litre tank hanging in the garage but not ready to part with it yet. I've seen a couple on TM for around the $400 mark so they do appear occaisionally or you could import one from safari tanks in aus. Think theirs are 15 litre or 25 litre if you really wanted to get serious.

Taz.

[Ocean1]

I've got the 13litre tank hanging in the garage but not ready to part with it yet. I've seen a couple on TM for around the $400 mark so they do appear occaisionally or you could import one from safari tanks in aus. Think theirs are 15 litre or 25 litre if you really wanted to get serious.

Taz.

This looks like a good deal: http://www.clarkemfg.com/cart/index.php?main_page=product_info&cPath=8&products_id=278

3.2 USG... Only 12.1L

Looks to be well built though...

[cooneyr]

If you get the factory MXC (close ratio 6 speed) 13l tank you need a different seat. The Clark and IMS 13l ish tanks and the Acerbis 25l tank all work with the stock seat. One of the Clark or IMS won't work with a fan kit but the other and the Acerbis will. I think it is the Clark but don't take my word for it.

This is a good place to get tanks from - Just Gas Tanks EXCTanks (http://www.justgastanks.com/store/index.php?main_page=index&cPath=1_17_158_233)

Oil coolers seem to be a little over rated. The HT kit adds about 500ml and you could possibly extend your service intervals slightly but most on ADV rider seem to reckon that you should just change your oil regularly and be done with it. I've foolishly read my way though all 140+ pages of this ADV thread - KTM 525 EXC as an Adventure Bike (http://http://www.advrider.com/forums/showthread.php?t=201026).

If you want to get really serious about abuse proofing the bike, stick some kibblewhite stainless steel valves (http://kpmivalvetrain.thomaswebs.net/) in it. I'm pretty sure Eurobike Wholesale in New Plymouth import them.

Can you tell what I'm lining up as a replacement for the 950 S ;)

[Eddieb]

KTM 525 EXC as an Adventure Bike (http://http://www.advrider.com/forums/showthread.php?t=201026).

Your adv thread link is broke, too many http://'s in it.

[CrazyFrog]

Get a case saver, money well spent if you ever flick a chain.
These ones in Oz are good, otherwise genuine KTM ones are around $120

http://cgi.ebay.com.au/Clutch-Case-Saver-fits-KTM-EXC-SX-Up-2007-/360289885194?pt=AU_Motorcycle_Parts_Accessories&hash=item53e2f35c0a

[Taz]

If you get the factory MXC (close ratio 6 speed) 13l tank you need a different seat.

No you don't. You can use the stock seat with the MXC tank. I do on my 05 exc.

[slowpoke]

I don't believe the bike needs an oil cooler in our climate but if you must the best one would be one of these (http://www.blaisracingservices.com/ktm/ktm-4-stroke-parts/ktm-motor/drive-line/01-07-ktm-400/450/525-exc/mxc/xc-oil-cooler/prod_233.html).

Taz.

It's not just about the cooling, it's about capacity. The pissy lil' oil capacity is what necessitates the frequency of oil changes. Upping the capacity means you you can push out the oil changes and spend more time riding and less time in the shed. :niceone:

[Taz]

It's not just about the cooling, it's about capacity. The pissy lil' oil capacity is what necessitates the frequency of oil changes. Upping the capacity means you you can push out the oil changes and spend more time riding and less time in the shed. :niceone:

What mileage are you pushing the changes out to? I change the 525 oil every 1500 to 2000kms. Compared to the 640 the 525 oil change is easy. Only takes 20 mins max. Could drain it in the cafe car park while having lunch and fill it before you leave :).

[Ocean1]

If you get the factory MXC (close ratio 6 speed) 13l tank you need a different seat. The Clark and IMS 13l ish tanks and the Acerbis 25l tank all work with the stock seat. One of the Clark or IMS won't work with a fan kit but the other and the Acerbis will. I think it is the Clark but don't take my word for it.

This is a good place to get tanks from - Just Gas Tanks EXCTanks (http://www.justgastanks.com/store/index.php?main_page=index&cPath=1_17_158_233)

Cheers. Half the reason for checking out bigger tanks is to change the shroud arrangement. NOT fixing shrouds to fuel tanks with PK screws seems to be an excellent idea to me. Integral shrouds in a natural (colourless) tank of 12 to 15L would be good.

Oil coolers seem to be a little over rated. The HT kit adds about 500ml and you could possibly extend your service intervals slightly but most on ADV rider seem to reckon that you should just change your oil regularly and be done with it.
Again, there’s an ulterior motive. Extra oil capacity does allow more contaminant tolerance and therefore longer service intervals but the biggie is the extra cooling interface. Cooling the oil takes a lot of load off the primary cooling system, which then performs better as a temp regulating system. If you can manage engine temp accurately you’ll extend not just service intervals but engine life.

If you want to get really serious about abuse proofing the bike, stick some kibblewhite stainless steel valves (http://kpmivalvetrain.thomaswebs.net/) in it. I'm pretty sure Eurobike Wholesale in New Plymouth import them.
Good advice. The top end’s just been done but at the first hint of noise from up there I’ll be tracking down some SS valves.

Can you tell what I'm lining up as a replacement for the 950 S ;)
Yeah. “Dual Sport” is an oxymoron, there’s really no advantage available from extra crap on a bike for the road that extra weight doesn’t blow completely out of the water in the dirt.
Wish the tyre compromise was as clear...

[Ocean1]

The OE zorst is rotten, muffler's in reasonable nick but the header is toast.

And it looks like none of the aftermarket system headers will match the OE muffler.

Of course.

So this caught my eye as a starter:
http://www.motoxparts.co.nz/motocrosspartsaccessories.php?category=94&brand=0&page=2&piece=1431

"Will it pass a WOF"? says I.

"It's MX legal in NZ" comes the reply.

Yeah yeah, I know, technically if it's under 95db it should be OK...

Anyone had experience with the brand?

[slowpoke]

The OE zorst is rotten, muffler's in reasonable nick but the header is toast.

And it looks like none of the aftermarket system headers will match the OE muffler.

Of course.

So this caught my eye as a starter:
http://www.motoxparts.co.nz/motocrosspartsaccessories.php?category=94&brand=0&page=2&piece=1431

"Will it pass a WOF"? says I.

"It's MX legal in NZ" comes the reply.

Yeah yeah, I know, technically if it's under 95db it should be OK...

Anyone had experience with the brand?

For what it's worth, I like the fact it looks like you can just un-bolt/screw the end cap which'll make repacking all too easy....especially if you are worried about WOF's and the like. Looks schweet too!

[Ocean1]

http://www.trademe.co.nz/a.aspx?id=324408838

It's off an '07, will it fit an '04 do you reckon?

[Crisis management]

http://www.trademe.co.nz/a.aspx?id=324408838

It's off an '07, will it fit an '04 do you reckon?

Hope so, looks like you bought it!

[Gremlin]

How abuse proof a bike in 3 easy steps:

1. Give to Gremlin
2. Let him ride it for 6 months or so (1 year if you want to test subframe etc)
3. All parts that break or mysteriously disappear are weak.

:facepalm:

[Ocean1]

Hope so, looks like you bought it!

Aye. I'll let you know in a couple of days eh?

Cheers Taz.


(1 year if you want to test subframe etc)

Some Adv doods are a tad worried about hanging a couple of Kg of luggage off dirt bike subframes. Have you SEEN the pounding them suckers take landing from a 20ft jump?

But then, I suppose they don't do that continuously for hours on end eh? Still, I figure, (given my advanced slothfulness) I'll be OK sticking a bag-roll across the back. Seen any good ideas there?

[Gremlin]

roll bag should be ok, keep it inboard as such, ie, where a pillion may sit. It means that area is designed for weight. I had a top box out back, the bouncing weight gave the subframe big issues, but since been strengthened

[Taz]

The giant loop bags look good. I just used a back pack and travelled light.

[Crisis management]

The giant loop bags look good.

This is the one I like, :woohoo: read some good reviews and I like the way they sit low on the bike.


http://www.giantloopmoto.com/products/coyote-saddlebag

[NordieBoy]

Some Adv doods are a tad worried about hanging a couple of Kg of luggage off dirt bike subframes. Have you SEEN the pounding them suckers take landing from a 20ft jump?

Have you seen the size of some of those ADV doods...

The subframes take a beating from getting on to the bike...

[Taz]

I've never ever abused my 525 :innocent:

[Ocean1]

I've never ever abused my 525 :innocent:

Why not? 'Swhat theyr'e for innit?

[Crisis management]

I've never ever abused my 525 :innocent:

You've certainly not put much wear on the front tyre.........

[CrazyFrog]

The giant loop bags look good. I just used a back pack and travelled light.

I just got back from a 1350km roadie in 3 days from Te Anau to Nelson on my 525.
Primo weather, primo roads. Nearly 500km of gravel or 4wd tracks.
1 oil change halfway, 1 fucked rear sprocket (poxy alloy), 2 missing bolts, one indicator vibed itself off. Oh, loctite is a must!
Bike already had a good Kings Tyre rear (not DOT) but rode it anyway, bloody good road manners and only 1/3rd worn, amazing wear.
Front tyre was a Pirelli Scorpion FIM which was worn and is now rooted, but also held the road well.
Travelled light with a 25 ltr backpack, no roll bags.
I highly recommend a seat upgrade, my arse is killing me.
Oh and earplugs, the Akra pipe is awesum! :woohoo:

[Taz]

I just got back from a 1350km roadie in 3 days from Te Anau to Nelson on my 525.
Primo weather, primo roads. Nearly 500km of gravel or 4wd tracks.
1 oil change halfway, 1 fucked rear sprocket (poxy alloy), 2 missing bolts, one indicator vibed itself off. Oh, loctite is a must!
Bike already had a good Kings Tyre rear (not DOT) but rode it anyway, bloody good road manners and only 1/3rd worn, amazing wear.
Front tyre was a Pirelli Scorpion FIM which was worn and is now rooted, but also held the road well.
Travelled light with a 25 ltr backpack, no roll bags.
I highly recommend a seat upgrade, my arse is killing me.
Oh and earplugs, the Akra pipe is awesum! :woohoo:

Excellent! Where are the pics??
Taz

[CrazyFrog]

Here you go all you 525 owners, I had a nice little ride this week.....

http://www.advrider.com/forums/showthread.php?p=14271924#post14271924

[Ocean1]

http://www.trademe.co.nz/a.aspx?id=324408838


Hope so, looks like you bought it!


Aye. I'll let you know in a couple of days eh?


It does. It came pre-plastered with duct tape inside the shrouds where, (upon careful and accurate investigation) it touches the outer rad frame bolts. Quite hard. There's no means of fixing the tank shrouds to the radiators so they're going to rub the fuck out of the tank. Already done a good starting job.

Wonder if an off-the-shelf radiator brace would make it work better...

If not I see a custom jobby in my future, with some rubber strips fitted into that outer rad frame rail.

Any vastly experienced and stunningly enlightening suggestions?

[Taz]

I just zip tied a couple of bits of inner tube to the radiators.

[Ocean1]

Here you go all you 525 owners, I had a nice little ride this week.....

http://www.advrider.com/forums/showthread.php?p=14271924#post14271924

Bastard.

Maybe next year I'll take the 525 to the Burt. This year I'm commited to taking the Buell.

I wonder...

[Ocean1]

I just zip tied a couple of bits of inner tube to the radiators.

Good. I like simple. Stops me spending stupid amounts of time re-inventing the wheel.

Thing is... I got some double sided tape, might try cutting a couple of strips of rubber slightly thicker than the channel in the outer rad frame and temporarily fitting them into the channel with the glue gun. Could apply some tape to the rubber and then spread the tank a tad and slip it on and lean on the shrouds to fix the tape. That'd give the radiators some forward / aft support too.

[Taz]

All that will cut into your drinking time ya know.......

[Ocean1]

I have straws. Just gota crush the ice really really small.

PS: do I have to empty the new tank before I attempt to correct some slight scratches with a propane torch?

[NordieBoy]

PS: do I have to empty the new tank before I attempt to correct some slight scratches with a propane torch?

Depends. Do you have a video camera?

[Ocean1]

Whelp, I spent several hours trying to chuck the beastie off the hills of Te Awaiti Station, (on the SE Wairarapa coast) today. What a splendid machine, intermediate tracks to be sure, (with limited oportunity to crash and burn properly) but what a pleasure to punt such a wonderfully capable machine around such magnificient country.

Still need to sort the zorst, and possibly an oil cooler, but if it's even passable on the road for 4 hours or so I rekon it'll do me.

*Giggles*

[Ocean1]

This dude here: http://www.trademe.co.nz/Browse/Listing.aspx?id=332243068&permanent=0 has a good deal on a set of wheels.

And I'm reasonably sure they'll fit an '04 beastie. Any advance on reasonably sure?

Anyone?

[Taz]

Says they'll fit from 03 onwards in the ad.

[cooneyr]

I can't actually help but doing some reading on axle diameters would be good start. If the same pretty good chance spacers will be OK and even if not then use your current spacers and change the seals.

[Ocean1]

Says they'll fit from 03 onwards in the ad.

Yeah, and they list 125 through to 530, but NOT a 525. I reckon it's a simple omission on the manufacturer's part.


I can't actually help but doing some reading on axle diameters would be good start. If the same pretty good chance spacers will be OK and even if not then use your current spacers and change the seals.

It's got custom spacers on it anyway, I made them from 316 to replace the fucked OE ones. If spacers is all there is to worry about I'll have 'em, I was more worried about basic hub dimensions and / or rim offset etc.

I'll call TSS, they orta have the part No's to hand...

Cheers guys.

[Ocean1]

Same part No's. Guess that's pretty conclusive. :niceone:

[Ocean1]

I've been abusing the 525. I've been trail riding. Nothing dramatic.

Anyway, the whole black plastic rear inner guard/taillight/numberplate/indicator assembly flapped around so hard it's falling apart. The plate gets continually bent forwards at the ends, fuckt if I know how that happens but teh plate's fuct now.

Anyone got the final, definitave fix? Or should I just get used to the idea that I've got 15min of changes to make before I hit the dirt. Guess I could make that easier with a couple of more strategically placed plugs...

Apart from that she's a ripper. :scooter:

[CrazyFrog]

I've been abusing the 525. I've been trail riding. Nothing dramatic.

Anyway, the whole black plastic rear inner guard/taillight/numberplate/indicator assembly flapped around so hard it's falling apart. The plate gets continually bent forwards at the ends, fuckt if I know how that happens but teh plate's fuct now.

Anyone got the final, definitave fix? Or should I just get used to the idea that I've got 15min of changes to make before I hit the dirt. Guess I could make that easier with a couple of more strategically placed plugs...

Apart from that she's a ripper. :scooter:

Same thing happened with mine, that tail piece is too long for trail riding, fine on gravel, but as soon as terrain gets rough, it bounces all over the place. My plate got so bent it started breaking away from the mounting bolts. I've seen a new 530 do the same, it bounced around so much it broke the mounting tabs off the underside of the tail piece.

I got hold of one of the short KTM enduro tail lights, and mounted my plate on that, which stops most of the stupid tail piece flexing. I will reinforce the number plate soon with a backing plate made of carbon fibre to protect the number plate more (alloy aheet would also do).
Just remember to switch the original tail piece back when you get a WOF, as the short enduro light doesn't have the white light for the number plate. :innocent:

Yes, the best solution is take it off completely if you're doing real trail riding and trailering the EXC to your ride location. You will also save those $60 indicators from bouncing off too.:bye:

[Ocean1]

I got hold of one of the short KTM enduro tail lights, and mounted my plate on that, which stops most of the stupid tail piece flexing.

OK, cheers. Any cheaper way to do that than presenting my arse at my local KTM dealer?


You will also save those $60 indicators from bouncing off too.:bye:

Too late for one of 'em. The new zorst singed the fuck out of the RH one.

[CrazyFrog]

OK, cheers. Any cheaper way to do that than presenting my arse at my local KTM dealer?

Yes, get the hacksaw out and cut the long one in half. Clear tape your rego to the top side of the rear fender.

Too late for one of 'em. The new zorst singed the fuck out of the RH one.

Look out for some DRC flush mount indicators and install them higher up on the tail piece. My Akrapovic pipe firstly melts the indicator, then blasts what's left of it into oblivion with the sonic boom it puts out:niceone:

[Taz]

You can also get number plate bolts with a little LED built in to illuminate da plate.

[Ocean1]

Yes, get the hacksaw out and cut the long one in half. Clear tape your rego to the top side of the rear fender.


Yup. *goes to look* No... it's a surprisingly poor design eh? Chopped down wouldn't reduce the mass much, it'd still flap around too much. I'll have to reinforce the top of the plate either way.



Look out for some DRC flush mount indicators and install them higher up on the tail piece. My Akrapovic pipe firstly melts the indicator, then blasts what's left of it into oblivion with the sonic boom it puts out:niceone:

DRC eh?

Onto it.


You can also get number plate bolts with a little LED built in to illuminate da plate.

Yeah, does that make the WOF man happy? 'Cause I know the enduro taillight assembly don't have the plate light.

[CrazyFrog]

DRC eh? Yes, DRC 586 indicators
http://www.cycletreads.co.nz/products/380-lights_and_indicators/2208-drc_motoled_flashers.aspxOnto it.

Yeah, does that make the WOF man happy? 'Cause I know the enduro taillight assembly don't have the plate light.

Yes again, fine with WOF testing station. They just gotta illuminate the plate, easy to wire up.

[CrazyFrog]

Seeing how this thread has kinda morphed into adventursing our EXC's, I've just added a new piece of kit to see me through some longer days on the bike.

My Baja Designs rear tank arrived from USA today in time for the Dusty Butt, so I spent some time in the man cave and had it all fitted it up within in an hour of unpacking it.
It holds around 4 litres, I haven't measured exact volume yet, so combined with the 13L front tank, this increases my fuel capacity to 17 litres now, should be good for about 270km.

http://i1205.photobucket.com/albums/bb424/waimiha-kid/BajaDesigns002.jpg

It has had some light use, got it off Ebay, so I expected some minor flaws, turns out it is pretty tidy, the only thing I'll do is replace the clear fuel hoses after a short road test.
It pretty much bolted straight on with only one minor mod, I had to drill the lower mount support bolt hole in the subframe and insert a M6 tap to leave a nice threaded insert.

http://i1205.photobucket.com/albums/bb424/waimiha-kid/BajaDesigns004.jpg

Yes, I know the rear tyre is shot, that's being changed this weekend :msn-wink:. The tank sits nice and flush but does not much clearance with rear tyre, I might silicon a carbon fibre protective plate on the inner sider of the tank in case contact is ever an issue.

I may still reroute the fuel hoses around the carb a bit tidier than shown, but this will do for starters.

http://i1205.photobucket.com/albums/bb424/waimiha-kid/BajaDesigns006.jpg

Next purchase, a Seat Concepts wider seat foam replacement. :drool:

[Ocean1]

Yes, I know the rear tyre is shot,

... and your seat mount bolt is gorne.

Nice bike, what year is it?

[CrazyFrog]

Seat mount bolt still sitting on the workbench, good spotting!

Mine is '06 525, with a '08 headlight and some flash stickers. :niceone:
ATM it has the stock tail piece and stock pipe on to keep the WOF man happy. Will refit the Akra and short tail unit after the DB1K. MMMMM, noise.

[cooneyr]

I was thinking about this thread today as I racked up another 300 odd kms. Tweaks to my 05 450 EXC so far include:


Acerbis 6.6 gal tank (25l)
Baja Designs H4 headlight and shroud
Trailtec side stand (stock on broke a couple of weeks before Christmas)
Clutch slave cylinder guard (can't remember brand at the moment SPR or something)
Home made bash plate
LC4 rear wheel with cush hub
SXS fork caps with adjustable preload (just cause they were cheep on Tardme and they are handy for when I change tanks re trail vs ADV rides)


Still have plans for the suspension but not much else on the to do list at the moment other than ride.

Trying to sort luggage (minimal) at the moment. Just enough for change of socks etc. Trial today with a bag tied to the tail didn't work so well. Bottomed out rear wheel removed it a couple of times. Either need to mod it or may still have an option on a very lighly used Giant Loop Mojavi.

Bike currently has 100 hours on it.

Cheers R

[CrazyFrog]

Sounds like most EXC owners are doing the same stuff to their bikes.

Mods since I bought mine @ 55hrs
Fitted larger factory 13L tank, didn't want Acerbis one, too much weight up front.
Fitted newer generation "08 headlight (for styling only), still has crap reflector but better 40/45W bulb.
High power LED aux lamps bought, will be fitted when daylight gets shorter.
Fitted LC4 cush hub rear wheel with Stealth steel sprocket
Heavier weight straight rate rear shock spring to cope with my 100kg bodymass.
Quick pull lever on front axle
KTM PHDS handlebar mounts, also help with raising bars a bit
Fitted OEM resin bashplate
KTM clutch slave protection, and bling oil filter covers
Enduro Engineering exhaust heat shield
Neoprene sleeve over shock lower heim bearing to help prevent water penetration
Ram mount for GPS
Foam rally grips coming ex USA, should be fitted for Dusty Butt
Fork service happening this week.

Bike now has 135 hrs.

Things I'd still like to do....
Seat Concepts seat foam/rebuild, can't afford a Renazco seat just yet
Trail Tech side stand when my one eventually breaks
Stainless oil drain bolt with 13mm head to replace crap OEM internal hex drain plug, it's a PITA
Factory Connection rebound housing on rear shock to prevent water corrosion in rebound adjuster
Like CooneyR, I'd like the SXS fork caps as well for easier adjustment.

The KTM 525 as Adventure bike thread on ADV is a dangerous place to visit, far too many ideas out there on the web.:drool:

[Ocean1]

Been grounded for a few months. Rotator cuff damage.

Thing is, it's not going to get any better, so I decided to take the 525 for a wee fang to see a) how much it hurts riding and b) if riding is at all usefull as an on-going shoulder excercise regime.

Decided to go see the brother up the Kapiti coast, via Karipoti, Mungatuks, etc. I was pleasently surprised that it didn't hurt too much, even pushing reasonably hard the only times I got the stabing ouchie thing in the shoulder is when the front stepped out a tad and I had to pull sideways on the bars to get back over the bike. Qualified success, then.

Got through the other side and onto the tarseal again and the bike died, out of gas behaviour. Checked everything I could, which wasn't much, gas supply good, visible spark. Had switched to res even though I didn't think I was anywhere near it, and some minute later it started.

Right. Stop at the gas stn, then. But it died the same way before I could get there. Same checks, no luck, had to call in the rescue team. At home, just checked the float bowl, (fine) and wondered what's next.

Anyone?

[young1]

Blocked tank breather? Take the cap off and then put it back on, make a difference?

[Ocean1]

Blocked tank breather? Take the cap off and then put it back on, make a difference?

No. One of the first things I did.

Good call though, identical symptoms.

[Mungatoke Mad]

Been grounded for a few months. Rotator cuff damage.

Thing is, it's not going to get any better, so I decided to take the 525 for a wee fang to see a) how much it hurts riding and b) if riding is at all usefull as an on-going shoulder excercise regime.

Decided to go see the brother up the Kapiti coast, via Karipoti, Mungatuks, etc. I was pleasently surprised that it didn't hurt too much, even pushing reasonably hard the only times I got the stabing ouchie thing in the shoulder is when the front stepped out a tad and I had to pull sideways on the bars to get back over the bike. Qualified success, then.

Got through the other side and onto the tarseal again and the bike died, out of gas behaviour. Checked everything I could, which wasn't much, gas supply good, visible spark. Had switched to res even though I didn't think I was anywhere near it, and some minute later it started.

Right. Stop at the gas stn, then. But it died the same way before I could get there. Same checks, no luck, had to call in the rescue team. At home, just checked the float bowl, (fine) and wondered what's next.

Anyone?Had the same thing happen to the 530 on Clareys rd died on the uphill about 500mtrs 4rom the top only had 60km showing on the trip tried res couple mins later I got her going about 200mtrs later backfired & died 5mins lata got her going over the top going down Rimu rd I turned the tap 2 on Position kept going till the top of the Pram track & same again 5-10 mins later going till just past Mcgees bridge Karapoti gorge 5 more mins to get her going again.
I cleaned my tank & carb fresh gas & a bottle of carb cleaner in the tank I've only had It happen 1ce since then in the dark on Waiotauru Rd over Easter

[Ocean1]

Had the same thing happen to the 530 on Clareys rd

Cheers dude, I'll check the tank and float bowl again tomorrow. When I've recovered from the effects of the Bourbon and Tequilla.

[NordieBoy]

Blocked tank breather?

[Ocean1]

Blocked tank breather?

No. Was also the 5th, 17th and 24th thing I tried.

Not going well, can't even find my fucking plug wrench, and I'm about out of time. Boys at the shop might get to sort it this time...

[dino3310]

the choke isnt stuck on is it.

[Ocean1]

the choke isnt stuck on is it.

Nope. It died just after a fairly hurried river crossing. Well, 2 min after.

And it died like it'd run out of gas, rather than the bullet-to-the-head usual when electrical stuff shit's itself.

It restarted 10min later, ran for 5 min and died again. Fin.

There's fuel flowing to the carb and it's getting past the float valve. The exhaust doesn't smell of gas, though, even after protracted cranking with the decomp open.

[Mungatoke Mad]

Nope. It died just after a fairly hurried river crossing. Well, 2 min after.

And it died like it'd run out of gas, rather than the bullet-to-the-head usual when electrical stuff shit's itself.

It restarted 10min later, ran for 5 min and died again. Fin.

There's fuel flowing to the carb and it's getting past the float valve. The exhaust doesn't smell of gas, though, even after protracted cranking with the decomp open.Mine would suck water in through the air box at any sort of speed thru river & water filled ruts . I put a rain cover over the air filter & sealed up all the cracks around the air box with some sellys all clear[ Except on the drain ] it made a big difference just have to check the rain cover every now & then as it tends to ride up the side of the air filter & needs to be pulled down every now & then.

[Ocean1]

Mine would suck water in through the air box at any sort of speed thru river & water filled ruts . I put a rain cover over the air filter & sealed up all the cracks around the air box with some sellys all clear[ Except on the drain ] it made a big difference just have to check the rain cover every now & then as it tends to ride up the side of the air filter & needs to be pulled down every now & then.

Cheers, good to know.

Don't think it got a lungfull of water, though, I checked the airbox at the time and it was was dry. Ish.

Besides, it ran for a kilometer after that.

[Ocean1]

Whelp, apparently the cylinder's toast.

And the coolant was half gorne. Wasn't any noticable leakage though.

Working hypothesis: head gasket fail, poor old dear sucked it up, got too warm and ripped a trench up the cylinder wall.

Didn't seize, just did enough damage to lose enough compression to die.

Bugger.


Any tips on sourcing new cylinder/piston?

[CrazyFrog]

Awwww bugger, that hurts!
This one http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/pistons-rings/auction-474155593.htm was on TM 2 weeks ago, sold for $300.

Option 1: Try looking up electroplaters to recoat the Nikisil coating on the cylinder and get a new piston.
Option 2: If you're considering downsizing to a 450 for the sake of a cheap rebuild, have a look at this one http://www.trademe.co.nz/Browse/Listing.aspx?id=481684717

Option 3: New factory parts $$$$ :weep:

[Mungatoke Mad]

http://www.bits4bikes.co.nz http://www.motocrossparts.co.nz http://www.mxshop.co.nz

[Ocean1]

Awwww bugger, that hurts!
This one http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/pistons-rings/auction-474155593.htm was on TM 2 weeks ago, sold for $300.

Yeah, saw that. Can wait a little for parts but given that it'll take me weeks to rebuild it I can't wait too long.


Option 1: Try looking up electroplaters to recoat the Nikisil coating on the cylinder and get a new piston.
Option 2: If you're considering downsizing to a 450 for the sake of a cheap rebuild, have a look at this one http://www.trademe.co.nz/Browse/Listing.aspx?id=481684717

Option 3: New factory parts $$$$ :weep:

1) Not confident with the replate.
2) Downsize? Make it smaller? with LESS torque?

Are you serious?

3) Will avoid if I can...

[Ocean1]

http://www.bits4bikes.co.nz http://www.motocrossparts.co.nz http://www.mxshop.co.nz

Cheers dude. If I believed their front ends I'd say thy don't have any. Or much of anything else for that matter. Fortunately I can see that their sites don't work very well, so I'll give 'em a call.

Edit: any reason to not put a high-comp piston in?

[MXNUT]

Cheers dude. If I believed their front ends I'd say thy don't have any. Or much of anything else for that matter. Fortunately I can see that their sites don't work very well, so I'll give 'em a call.

Edit: any reason to not put a high-comp piston in?

Give these Guys a call http://www.o2engineering.co.nz/

They resleeved my DRZ400 barrel for me and i put in a forged hi comp piston. $270.00 for the sleeve.

Been in the automotive industry for 25 years and have never seen a sleeve job done with such precision.

Could not tell it from a new part. :yes:

[Ocean1]

Right. A re-chromed cylinder, piston, stainless valves and a camchain, (replaced on suspicion). Thanks to the guys at TSS for some nice work.

Took a wee run-in pootle down Karipoti and out the Mungatuk end to see the brother and back the same way. Had me worried towards the end, there, but it was just hitting reserve a tad earlier than anticipated.

Apart from being a bit of a bitch to start cold, still she's all good. Bit of attention around the valve seats seems to have paid off with slightly more rip up top and it's nice and crisp through the middle.

Bit of dribble on over-run since I put the DRD full system on it, must rejet to suit before too long. New oil and filters tomorrow and we're good to go.

[cooneyr]

Thread dredge but it is the only EXC thread in the Adv section.

EXC riders might be interested in these. Cush drive real wheel being the useful bit. Should slot straight in with your current axle (pre 2008 model EXC - not sure about 2008 on)

http://images.trademe.co.nz/photoserver/tq/0/237407700.jpg (http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/wheels/auction-523620003.htm)

http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/wheels/auction-523620003.htm

Cheers R

[Ocean1]

Not a bad price if it don't go much over the startong price.

That rear looks big... can't be a 19", though.

[cooneyr]

Not a bad price if it don't go much over the startong price.

That rear looks big... can't be a 19", though.

All 640 E's that I know of have 21/18 combo. Be good deal for start price.

Cheers R

[Waihou Thumper]

:lol::lol: Now that would be some bike! :)

[brp]

Check out this site: http://www.dsadventures.com/525reviews.htm

You'll never look at an over priced XR650R again.

"Economy of scale"

Dude I bought motard rims off his XR had done 80,000 KM and was just starting to use bit of oil
on a motor that have never been touched - on a good day that's 8 - 525 rebuilds :D