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.

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.

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.

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....roducts_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

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.

If you want to get really serious about abuse proofing the bike, stick some kibblewhite stainless steel valves 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.

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-S...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.

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.

[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.

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

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 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/motocros...e=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/motocros...e=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!