2007 KTM 525 exc
Darko

Australia

#21 Oct 9, 2007
Chazmanian,
You're a champion! I've been reading crap for months on the 525 as I'm looking to get a new one and everyone keeps sayin this or that about them. What you have said is spot on and I'm glad to hear it from someone who sounds like they know what they're on about. Thanks for the setup tips, I'll make sure to keep them for when I finally get it
Chazmanian

Denver, CO

#22 Oct 9, 2007
No problems at all Darko! I assure you that the KTM 5252EXC is right at the very top of the off-road race ready machine food chain! This is a world championship winning machine that is raced in local enduros all the way up to the Dakkar! These bikes are raceable at the highest levels in fairly stock form. There are a few critical issues that must be addressed prior to riding the KTM EXC or most any other true race bike. Jetting, Exhuast,Gearing. It bothers me to see that there are dealers who will sell these world class bikes to "Civilians" without prior motocross or enduro backgrounds. Very sad indeed. The KTM 525 is a serious off-road weapon that is fast enough to easily killl a first time off-roader who dosent understand that race bikes need bolts torqued, gearing changed and carburator jetting prior to really riding it. These are not street bikes! These are true race machines that happen to have a tag, lights and blinkers. The EXC is an XC with the lights but KTM puts a restrictor in the exhuast and a very tall gear ratio. A gear ratio tall enough to carry a stock KTM 525 to well over 100MPH on any hard surface. A guy thats not smart enough to check bolts on what is essentially a "Dirt Bike" has no place on the roads driving around my wife and kids on one of these bikes without some help from someone who knows whta they are doing. In the wrong hands a KTM 525 is a death sentance. In the right hands it is an uncompromised assualy weapon ready to take on the fastest off road bikes and races in the world today.......What would the guy who dosent understand jetting, gearing and bolt torquing do when his knobbies swelled on the freeway going 100 MPH and burst sending him to an early grave? Because if you cant check the basics you sure dont have a clue wht PSI to run in the tires of one of these bikes.

To the Newbs...Go to KTM.Talk.COM or Thumpertalk.com and garner some info on your bikes! To the experienced guys....See Ya on the trail!!!

[IMG]http://i162.photobucket.c om/albums/t243/chazmanian_2007 /K2-1.jpg[/IMG]
Chazmanian

Denver, CO

#23 Oct 9, 2007
Here are some photos of my 2007 525 EXC. I have changed out all the stock plastic, graphics added a larger fuel tank, rejetted, regeared, added desert race tires, a scotts steering stabilizer, silicone hoses, front and rear springs to match my weight and riding ability,skid plate, brake fin, handguards, carbon fibre pipe protectors. All the above is almost mandatory on one of these bikes. Be prepared to have a pure-bred world class race machine that you will have invested well over 10K in before its said and done!
[IMG]http://i162.photobucket.c om/albums/t243/chazmanian_2007 /Pipe.jpg[/IMG]
[IMG]http://i162.photobucket.c om/albums/t243/chazmanian_2007 /K1.jpg[/IMG]
[IMG]http://i162.photobucket.c om/albums/t243/chazmanian_2007 /KFront.jpg[/IMG]
[IMG]http://i162.photobucket.c om/albums/t243/chazmanian_2007 /K2-1.jpg[/IMG]
[IMG]http://i162.photobucket.c om/albums/t243/chazmanian_2007 /Scotts.jpg[/IMG]
tfw-santa fe

Albuquerque, NM

#24 Oct 14, 2007
Chazmanian wrote:
<quoted text>
The real issue here is that folks need to understand that the KTM 450/525 EXC are RACE BIKES with a tag and lights. Period. The RFS KTM motors are legendary in offroad racing and are widely considered to rank right up there with the Honda XR motors in reliability. This still doesent cahnge the fact that these are purpose built racing machines and are really not meant or marketed towards the casual rider who cant wrench on a bike. Simply put KTM restricts the 2007 EXC 450's and 525's with very lean jetting and a very restricted exhaust systen to pass EPA in all 50 states. So it takes a person with a slight bit of mechanical skill to get the bike running off the showroom floor. This bike is marketed towards experienced racers who want a street legal bike as well to connect the trails. This group of riders understands that the EPA crap is easily removed and the bike is easily rejetted. As with any race bike the bolts must all be retorqued opun delivery either by you or your dealer. The bike will never also jet correctly until the exhuast restrictor is removed. It also will not ride at its true potential until the rear sprocket is changed as the stocker is a 45 tooth thats put there to pass noise laws and keep RPM's down.
I own a 2007 KTM 525 EXC. I haved raced and ridden offroad bikes for 20 years. The KTM is hands down the best bike I have ever owned....I also understand race bred machines and dint even ride the bike until I rejetted the carb removed the exhuast restrictor, added a coolant recovery tank and regeared the bike. I also tightened all the bolts and locktited those pesky kickstarter bolts~! This bike qwill rip up the hwy at 90MPH+ and then proceed to attack the narliest scariest single track Colorado has to offer. This is the same bike that Juha won the world enduro championship on. World class machine with world class componetry. Its a race bike. The dealer who sold you this bike without "Vhecking Your Credentials" did you a misservice. He should have sold you a Suzuki DRZ or a Honda XL650. This bike is way over the riding level of someone who dosent understand race machines. Every racing four stroke on the market will overheat in the hands of a Novice rider. Your dealer did you dirty. KTM RFS 525's and 450's are a bike for fast capable experienced riders.
Go trade it in on a slow heavy unraceable turdish Honda or Suzuki.Leave the KTM's on the showrooms for the guys who know how to use them!
totally agree that KTM's are race bikes, finely tuned and thus finely out of tune if you don't know what you are doing...I personally have learned alot more about bikes since I bought my 525....let me know what coolant recovery system you used...does the fan really do anything?

thanks

[email protected]
Chazmanian

Denver, CO

#25 Oct 14, 2007
I went with the Thumper racing CRT as it mounts low on the frame by the motor and I can lean over and look at it to see if the overflow tank is spitting coolant. So far so good. The key on the RFS bikes is to keep your speed up around 8MPH if at all possible and dont run in to tall of a gear or lug around too much as the water pumps impeller needs to be spinning fresh coolant into the motor. I didnt want the fan as I like my E-Start button too much to take a chance on running down the battery with the fan. Mine dosent overheat with this CRT installed and if it does it simply sucks the expelled coolant right back out of the overflow cannister as soon as you get moving and on the gas.$80.00 for the good CRT. Powder coated black like the frame and not some plastic tank mounted under your rear fender with its weight too high on the subframe. I added a set of CV4 silicone race hoses to the motor as well....They work well.
[IMG]http://i162.photobucket.c om/albums/t243/chazmanian_2007 /PIC01459.jpg[/IMG]
[IMG]http://i162.photobucket.c om/albums/t243/chazmanian_2007 /PIC01461.jpg[/IMG]
soccerdude

United States

#26 Oct 16, 2007
I bought a new '07 450 EXC. Sripped off the EPA garbage and slapped some Maxxis 6006 tires for the stock Six Days. Put some barkbusters on and a skid plate. Torqued the bolts and consistently check them every couple of weeks. Change the oil and oil filters every 30 hours. Air filter every other oil change. 1500 miles of pure nirvana on gravel, hard pack dirt and pavement. Makes my crotch rockets seem lame. I commute 20 miles each way mainly gravel and blacktop. Usually run 60 MPH on the gravel and 65-70 on black top. Doesn't overheat and doesn't disappoint. Next mod will be a larger gas tank and brighter headlight (still need to keep it street legal - spend most of my time on gravel and blacktop).
Love my Yamaha R6 but like my KTM better. Next purchase will be the 690 Adventure (it's coming). Then I'll convert this to a supermoto. Got a 2 stroke 200 KTM also and this '07 rocks!
Chazmanian

Denver, CO

#27 Oct 18, 2007
soccerdude wrote:
I bought a new '07 450 EXC. Sripped off the EPA garbage and slapped some Maxxis 6006 tires for the stock Six Days. Put some barkbusters on and a skid plate. Torqued the bolts and consistently check them every couple of weeks. Change the oil and oil filters every 30 hours. Air filter every other oil change. 1500 miles of pure nirvana on gravel, hard pack dirt and pavement. Makes my crotch rockets seem lame. I commute 20 miles each way mainly gravel and blacktop. Usually run 60 MPH on the gravel and 65-70 on black top. Doesn't overheat and doesn't disappoint. Next mod will be a larger gas tank and brighter headlight (still need to keep it street legal - spend most of my time on gravel and blacktop).
Love my Yamaha R6 but like my KTM better. Next purchase will be the 690 Adventure (it's coming). Then I'll convert this to a supermoto. Got a 2 stroke 200 KTM also and this '07 rocks!
Soccerdude...Is your 30 hour oil change interval a "Typo"? You obviously know what you are doing and have a good grasp on servicing and wrenching on your machine.....I would hope that 30 hours is a typo though. For those non-mechanics that started this thread in the beginning...The RFS motor holds 1.2 liters of oil. This is not much oil for a high performance machine that inherently operates at high temps. Change the oil in your KTM RFS bikes every 3-6 off road hours or 8-10 street hours. Insure that the valves are adjusted intially at 10-15 hours and then every 20 hours thereafter. They will take a set after the first two adjustments but tighten up and cause lowered performance and harder starting as the gap closes.

Soccerdude, Its good to see that a guy like you who understands and appreciates fine machinery got yourself a 525. Great bikes. Possibly one of the greatest dirtbikes ever produced by any country anytime. The RFS motors will go down in history right next to the legendary Honda big bores. The exception is that the KTM RFS motor is lighter and produces way more power all through the RPM Range.

The new bikes with the new XC4 motors are out now. That motor is based of last years SX motor. I'm steering clear until the bugs are worked out as I have heard the new motors do have a few little issues. Oil leaks, etc. the 2007 RFS motor was the pinnacle of perfection. I will keep my 525 for the next 8 years! My next KTM will be fuel injected and make my toast in the morning.
Kevin Whitener

Aurora, OH

#28 Oct 22, 2007
I bought a 07 525exc and sometimes I will be rideing it and it will act like it is runing out of gas and cut off. When I take the gas tank off it will start right up. If anybody could help me out it would be greatly apreciated.
thanks, Kevin
Chazmanian

Denver, CO

#29 Oct 22, 2007
I'm confused??? When you take the gas tank off it will start right up?? Are you saying that you are actually removing the tank and the fuel hose from the carb?

Typically if you have issues with KTM's and fuel tanks it could be a few diffrent things.

#1. The two throttle cables are short and designed to fit snugly between the tank and the upper frame rail. Make sure you are routing the throttle cables correctly. You can tell if they are not correct by starting the bike and turning the handlebars from side to side. If the motor revs up or down you have them installed improperly. Fix em'.

#2. Is there a kink in the fuel line from the petcock (Gas on off valve) check that there is no debris or kinks in that line from the tank to the carb.

#3 Did you de-cannister and de-emission the bike? Meaning have you removed the catch can located by the pivot of the swingarm? and have you removed the cannister behind the shifter side number plate? Also the pipe needs to be removed and have the restrictor cut out.

E-mail me at [email protected] if you need instructions.

#4. Is the carb jetting stock? If so its too lean and your bike wont run well at all....The stock jetting is just a way to get the bike 50 state street legal and its not meant to be ridden like that. It is way too lean and must be rejetted or it just wont run at all.

#5. How many hours on the bike? The exhuast valves will tighten up at about 12 nours on a new KTM RFS making it hard to start and it will run funky. Get the valves adjusted to specs if you havent done so already.

Here are some basics that are often overlooked:
Is the gas fresh?
Is the gas 91 Octane?
Is your air filter packed with dirt?
Is your spark plug grimy and gross?
Have you changed the oil?
Do you know how to adjust the idle?
Do you know how to adjust the fuel mixture screw at the bottom of the carb?

Cover all the above and I promise you will have a great running bike that will last you many years and smoke most of your buddies on any trail....

Keep in mind although this bike is sold as a street legal dual-sport its really not. Its a bike that needs a mechanic to set it up correctly when first purchased and a bike that will demand rigourous maintenance and lots of oil changes, valve adjusts and bolt torque-ing. This is a racing enduro bike that was "Snuck" ikto our country under guise of being a dual sport bike. Its just a race bike with lights and not a good choice as a daily commuter or DRZ/XL650 type bike replacement.

They run hot and they are designed to be moving foward! Stoplights and traffic jams are not your friends when riding a KTM RFS. The bike will need a fan kit and coolant recovery tank to meet those requirements. Thats after doing all the above!

Shoot me an e-mail if you need help.
iramir2007

Norristown, PA

#30 Nov 5, 2007
i just bought an 08' 525 the only thing i have a concern is, is it supposed to be this loud. i mean this thing is the loudest bike i've ever rode. is this normal or am i the only one ????
Nessy

Brisbane, Australia

#32 Nov 11, 2007
Chazmanian wrote:
<quoted text>
Go trade it in on a slow heavy unraceable turdish Honda or Suzuki.Leave the KTM's on the showrooms for the guys who know how to use them!
I understand were ur coming form mate but it still dosent make up for the faults these bikes have. Any other japanese bike performs as well the kato if not better yet they do not boil, they do not strip bolts or have any other little faults. These bikes should not be used for comuting, they are a race bike but unless you can pay for the stupid prices for spare parts, stand the massive backorders for critical parts and put up with their faults then you should shop elsewhere. Go grab a yamaha, theyll destroy a ktm on the track and let you ride home in the arvo without a fault. Ktm's are not that good of a bike, take it from somone who works in the industry, 4 month backorders on pistons, bike that are broken in the boxes when they arrive and mor warranty claims than all the other brands put together. The Austrians just cant build a reliable bike.
viz525

San Clemente, CA

#33 Nov 12, 2007
the first thing you want to do with the 07 525exc is cut out that damn restrictor, jet the sucker and (no more) overheating has been accomplished, also throw a $95.00 fan from ktm on the beast and she'll love you forever! oh yeah, and also keep fresh oil in her! She'll work better for ya if she's lubed and her valves have been adjusted! don't be scccuured it's easy maintanence. LONG LIVE RFS!!!!!
Chazmanian

Denver, CO

#34 Nov 20, 2007
Nessy wrote:
<quoted text>
I understand were ur coming form mate but it still dosent make up for the faults these bikes have. Any other japanese bike performs as well the kato if not better yet they do not boil, they do not strip bolts or have any other little faults. These bikes should not be used for comuting, they are a race bike but unless you can pay for the stupid prices for spare parts, stand the massive backorders for critical parts and put up with their faults then you should shop elsewhere. Go grab a yamaha, theyll destroy a ktm on the track and let you ride home in the arvo without a fault. Ktm's are not that good of a bike, take it from somone who works in the industry, 4 month backorders on pistons, bike that are broken in the boxes when they arrive and mor warranty claims than all the other brands put together. The Austrians just cant build a reliable bike.
When you say "Any" other Japanese bike performs as well as a Kato....Under what context is that statement made?

When you state that the Jap bikes dont boil I begin to question your claim of being in the industry...Or even having a clue. If you had any sort of clue you would know that the Jap bikes come with coolant overflow tanks and boil just as often at low speeds. Plus what full blown enduro race bike does Japan sell thats street legal off the showroom floor. Maybe down under but not in the good old USA brother. Hence the lean jetting and the restricted exhaust.

Go grab a Yamaha they will destroy a KTM on a track????

So is it the rider or the bike? KTM builds bikes that cover a huge range of racing. They have as many two stroke models as yamaha has total models! KTM dominates all forms of enduro racing. When was the last time you saw a competitive yamaha at the world enduro chalenge? Or at the baja 1000? Or in Dakkar? Or literally showing up at every hare and hound and harescramble race across the country and typically dominating?

Stripped bolts? KTM bolts are the best in the industry dude...What part of the industry did you say you worked in? It cant be anything mechanical. You a Yamaja salesperson?

You state Yamahas have no faults? I state that you my friend should go back to the showroom floor and close some deals.....I say that you havent clue as to what you speak of and are painfully unaware of Yamaha shortcomings in the enduro class. The WR450F is a boring uncompetitive turd in need of a makeover. The Yamaha 4 sdtroke is a valve eating high maintenance nightmare that isnt able to be ridden on the street for any extended periods of time. Everyone knows that...Except you.

So go grab a yamaha and do what? This isnt a Motocross blog or discussion mate. Its a discussion about a street legal enduro bike that is highly regarded as the best ever made but needs a bit of work to make right.

Yamaha? Pffft. I see your WR450F and raise you massive amounts of shiny gold trophys adorning many a KTM riders mantle.
andy

United States

#35 Jan 14, 2008
read the owners manual first. go to ktm talk. i have an 07 525 exc NO PROBLEMS. i ride florida 80+degrees high humidity deep sand tight trees 60 to 120miles + 80 to 100 miles street 75+mph to get to richloam+onf, i am 240lbs with gear on.
I pull drain plug after 3/400miles about 1qt mobil 1 10/40 then full change every 3rd change.
original coolant have not lost a drop.
bike set up- jd jet, set up just a little rich, power now intake wings, leo vince pipe, fan kit.
flex bars, scotts,magellen,clark tank,cf pan,probend+cycrahand guards.I have not had any problems with any of these accessories.
This is a competition bike first not a trail bike you need to treat it like one. TORQUE wrench and good tools will solve many maint problems.
Sorry for the soap box rant.
Now go and ride :-}
paul6898

Seattle, WA

#36 Jan 23, 2008
Hello,
Does anyone here know much about Sherco's? Specifically a 2005 4.5i. I am a large 40yo rider who is done with my wr450 and would like a dual sport to tackle trails, logging roads, etc. I am too old and fat to single track anymore and really don't ride aggressive. I was leaning toward a KTM 525 or 530, but reading these posts makes me think not. I am also not a mechanic and frankly would rather pay someone at this point to work on my equipment. Any advice is appreciated.
Chazmanian

Denver, CO

#37 Jan 24, 2008
You will have all of the issues associated with a High performance enduro race bike convert with the Sherco as you will with the KTM.....Except for one bigger issue.

Where do you buy parts for a Sherco?
How many Sherco dealers have you seen lately?

That Sherco is Fuel Injected....Inherently that system may fail you in the middle of nowhere. then what? Who can you call? What can you do?

I say no to Sherco. This aint Italy and there isnt much factory or aftermarket support for a Sheroc in the good old US of A.

Not a mechanic? Probabably not a Sherco buyer.

Why not a properly set-up KTM?

Or even a sweet new Husqvarna 610?

Maybe a leftover Honda XR650?

Done with the WR450? Thats a high maintenace machine. Valve wear?

I think a guy who is really not gonna be on the streets but wants to haul the mail on fire roads and trails should give the 2008 KTM 300 XCW 2 stroke a serious look. More HP than the 530's and 525's super low maintenace and an E-Start for 2008.

300's are like 3 strokes. Pure thumping power with many moving parts.....Oh yeah they are about $1000 cheaper than a 530/525 as well!!!
mitch

Mount Vernon, IL

#38 Jan 27, 2008
Chasmanian,
I couldn't agree with you more I have put many bikes through there paces and KTM is simply the best. Like you said earlier if a person is going to buy a KTM they better ride it like a KTM! I have just recently purchased a 07 525exc and I love it. The first four gears are great for offroad and fifth and sixth are long for street application. I would love to put it up against any WR450. I have already raced a KLR650, and DRZ 400 and needless too say my KTM put them in there place.
Blaster

United States

#39 Feb 10, 2008
I'm sueing KTM for this. I just spent over $9000.00 for this bike and it stranded me about 8 miles from camp. I had to walk it through deep sand whoops back to camp. I have owned a 3 KX's,2 RM's and a 4 YZ's. They never stranded me like this EVER!. I am pissed.
Blaster
Blaster

United States

#40 Feb 10, 2008
My bike got so hot my gas was boiling, straight up.
Blaster
kit

Seattle, WA

#41 Feb 11, 2008
Chazmanian: Is the Husq. 610 low maintenance? There's only one dealer near Seattle Metro area.
Do you think the new '08 Yam. dual-purpose WR250R (street legal), will likely be an engine-issue bike? Weight is 275. I think everyone really appreciates your ability to explain the reality of riding and owning the various bikes. Btw, fire roads here don't allow anything but street legal. I'm now trying to figure out what trails I could conceivably use a two-stroke on in washington state.
Chazmanian wrote:
You will have all of the issues associated with a High performance enduro race bike convert with the Sherco as you will with the KTM.....Except for one bigger issue.
Where do you buy parts for a Sherco?
How many Sherco dealers have you seen lately?
That Sherco is Fuel Injected....Inherently that system may fail you in the middle of nowhere. then what? Who can you call? What can you do?
I say no to Sherco. This aint Italy and there isnt much factory or aftermarket support for a Sheroc in the good old US of A.
Not a mechanic? Probabably not a Sherco buyer.
Why not a properly set-up KTM?
Or even a sweet new Husqvarna 610?
Maybe a leftover Honda XR650?
Done with the WR450? Thats a high maintenace machine. Valve wear?
I think a guy who is really not gonna be on the streets but wants to haul the mail on fire roads and trails should give the 2008 KTM 300 XCW 2 stroke a serious look. More HP than the 530's and 525's super low maintenace and an E-Start for 2008.
300's are like 3 strokes. Pure thumping power with many moving parts.....Oh yeah they are about $1000 cheaper than a 530/525 as well!!!

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