Project 525EXC Dualsport

[joker650]

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ran the tank down to where the round becomes square (at the shrouds) then stopped in at a gas station. I had 37.5km. I put 2.1L into the tank. That's 17.86 mpg. The tank is 3.2Gal (12.11 L), so that means I have a range of 134miles (216km). This is craptacular. The ride next week in Kamloops is 200kms approx, and there's not a convenient gas stop along the way really. It'll be a squeaker.

It's ok paul......the ride has been cut down to about 150km. Now the Creamcycle Crew can make the trip. Hope u guys don't mind riding with an underpowered Dr650:mad3:

 

[Island Hopper]

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You mean 17.86 KM/PL = 41.88 M/PG not too bad for a dirt bike. Of course your old 640 probably did a little better on fuel than that but probably didn't pull wheelies quite as easy.

 

[ElChupacabra]

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Island Hopper wrote:

You mean 17.86 KM/PL = 41.88 M/PG not too bad for a dirt bike. Of course your old 640 probably did a little better on fuel than that but probably didn't pull wheelies quite as easy.

The 640 did a little better I think, and it was willing to wheelie when the tank was really low. Do the carb mods (drill slide, cut few coils off spring, jet properly) and uncork (side airbox screen, add disks to Supertrapp or Aftermarket exhaust) and the throttle response improves significantly. But the 525 easily wheelies in 4th gear at 70km/h+, and still has 5th and 6th gears to take you up to 160km/h (I would never ride this fast ever, nor have I tried). Finally my bike has the same torque as Joker's DR650!!

KTM LC4 (640) Index Thread on adventurerider.com is a great starting point for all things to do with your bike.

I knew that with the 525 fuel capacity would be an issue, I was used to riding the supertanker, my goal was 200 miles range. By adding the Baja Designs tank I'm pretty close.

Before my trip to Mexico this fall with the advrider guys (which have the 6+ Gallon tanks) I will probably pick up the Acerbis 25L tank (and some stiffer fork springs). I don't want to be the guy who's always running out gasolina.

 

[Hooligan]

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Paul,

What you doing for tyres on the road.?

:hb:

 

[joker650]

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Island Hopper wrote:

You mean 17.86 KM/PL = 41.88 M/PG not too bad for a dirt bike. Of course your old 640 probably did a little better on fuel than that but probably didn't pull wheelies quite as easy.

Sorry to put a lowly DR in this thread but........

I just checked my mileage on the 650 and I had 212km of highway to work and back , usually doing 115-120kph, and used 11L of fuel...works out to 54.4mpg.This was after I drilled the slide, raised the needle and opened the airbox a little., before it was about 40mpg on the same route.

Finaly over 200km's per tank.....hmm, if I stay off the throttle I may be able to hit 250km's,,naww:ted:

 

[ElChupacabra]

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Hooligan wrote:

Paul,

What you doing for tyres on the road.?

:hb:

Shhhh I'm running the stock Bridgestone Motocross tires currently...:mb:

But I have a pair of Pirelli Scorpion Pros to put on, and a pair of Dunlop 908RallyeRaids to try out as well. Not sure what will go on first.
:tup:

 

[Hooligan]

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Paul,

I am buying oil cooler for the 450....:dr:

Why did you opt for that oil cooler rather than the Joe Racer's as used on the Dakar 525's?

You got a better idea of fuel consumption by now?

:hb:

 

[Mac525]

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I have an 05 525 and I'm haveing problems finding a halogen head light because the stock 30/30 watt really sucks and the new 60/60 watt is just put in is a little better but not really enough to ride by ??? What fixes have you guys come up with??

 

[ktmkim]

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I think the best option for lights is a helmet mounted HID. I have the Acerbis dual light on my bike, the best DOT light I could find and I can only putter along offroad at night. Works OK for the street but marginal offroad.

Kim

 

[Mac525]

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I got a bosh part number from a guy on the KTM talk site for a halogen bulb BA20D and I'm going to get lordco to bring one in and try it]:ss:

PS that boshe number does not come up so I;m still hunting for some thing else

 

[Sixgill]

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Mac525 wrote:

I got a bosh part number from a guy on the KTM talk site for a halogen bulb BA20D and I'm going to get lordco to bring one in and try it]:ss:

PS that boshe number does not come up so I;m still hunting for some thing else

Depends on what your willing to do for lighting.... I went with Hella Lamps and HID Bulbs.

Hella FF50 & FF75 series worked for me. They are bright enough that drivers will pull over for me in the Day time!

 

[Mac525]

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wow i really like the look of the light but i wold have to go to the old number plate to do it looks cool though I would like to see how you wired it all together ... I can't say i like the look of the tank though that must be the 25 leter one if you are down this way let me know we can go for a little boot

What other head light fixes have you guys tried is there a bulb that I haven't found yet???

 

[atswilson]

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I see that you found a brake switch for a KTM where did you find this I need one for my bike

Thank You

Tony Wilson

[email protected]

 

[ElChupacabra]

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atswilson wrote:

I see that you found a brake switch for a KTM where did you find this I need one for my bike

Thank You

Tony Wilson

[email protected]

It came as part of the kit from CycleZone which included the new wiring harness and all switches etc...

 

[ElChupacabra]

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Mac525 wrote:

I have an 05 525 and I'm haveing problems finding a halogen head light because the stock 30/30 watt really sucks and the new 60/60 watt is just put in is a little better but not really enough to ride by ??? What fixes have you guys come up with??

I rode with a guy who had the Baja Designs Tecate HID setup. I followed him like a moth in the dark when we were riding in Mexcio. I see on the BD website they have a HID kit for the 2007 EXC. Their website is a piece of crap, so I can't get any details.

 

[ElChupacabra]

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Sorry for the late replies, we moved to a nice rural acreage with NO HIGH SPEED INTERNET, so I'm not online much.:? I'll have high speed by the end of the month hopefully...

 

[hookeniggy]

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Power?

Try a late 90's 495 , you want be impressed no more, period.

iggster

 

[PaulBurke]

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Sixgill wrote:

Mac525 wrote:

I got a bosh part number from a guy on the KTM talk site for a halogen bulb BA20D and I'm going to get lordco to bring one in and try it]:ss:

PS that boshe number does not come up so I;m still hunting for some thing else

Depends on what your willing to do for lighting.... I went with Hella Lamps and HID Bulbs.

Hella FF50 & FF75 series worked for me. They are bright enough that drivers will pull over for me in the Day time!

Sixgill, did you ever post details on this awesome HID mod?

 

[5thgear]

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Nice bike. To bad I wasted $7399 on my TE 450 Husky that all ready came street legal.

But that headlight is pretty kick ass. Drop it buy the shop sometime I'd like to see how bright it is.

 

[PaulBurke]

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5thgear wrote:

Nice bike. To bad I wasted $7399 on my TE 450 Husky that all ready came street legal.

Don't beat yourself up, you surely won't make that mistake again. You really paid yourself $7399? If it were me selling bikes, I'd have given it to me at my cost.

The 525EXC turned out to be a great adventure bike, BTW.

Paul aka Elchupacabra