Abuse-proofing a 525

[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

[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

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/product..._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.



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.



Yes, I know the rear tyre is shot, that's being changed this weekend . 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.



Next purchase, a Seat Concepts wider seat foam replacement.

[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.
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:

1. Acerbis 6.6 gal tank (25l)
2. Baja Designs H4 headlight and shroud
3. Trailtec side stand (stock on broke a couple of weeks before Christmas)
4. Clutch slave cylinder guard (can't remember brand at the moment SPR or something)
5. Home made bash plate
6. LC4 rear wheel with cush hub
7. 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.

[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?