Project 525EXC Dualsport

Buck

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Nice fuel tank. What's the capacity? Tell us about the tires. Milage, traction, your opinion, etc.
 

PaulBurke

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00Buck wrote:
Nice fuel tank. What's the capacity?
25L Acerbis - awesome. Bumped up to stiffer springs in the front to acoomodate the added weight.

00Buck wrote:
Tell us about the tires. Milage, traction, your opinion, etc.

Dunlop 908Rallye Raids. I like them, and they suit the BC Interior and Mexican mountain/desert riding. They're not at home in muck, but elsewhere they shine. They are super tough carcassed tires that you can run practically flat and still not ding a rim or pinch-flat. I have them on front and back. Ultra heavy duty tubes, and NO FLATS - yet. I'll have to check my maint. log and see how many miles I get outta them-but so far I've seen them last longer than the Pirelli Scorpion Pro, MT21, Maxxis DesertIT, stock Bridgestones...
 

shoobear

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Hey tell me about what u did to your forks.

I am getting the same tank and will have to adjust the forks.....
 
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tazzman02

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Does anybody have the part number of that light/kill/horn switch thats pictured in this thread? Does it put up with the wet? Thanks
 
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06exc400

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Hi all:

I just did a conversion on a New 06 exc 400. I did not order the parts but made the harness myself "16 hours of soldering etc" I have seen and read about a few items on the 525 project. I want a set of bags and those one look great, What Brand/Make? I also read something about a friends 400 upgrade. Is this the 525 barrel and piston and if so, what cam was used? Jetting? I am almost done on my project, it was cold as I was doing it outside in Dec. Any info you can share would be great.



Thanks

Rod
 

joker650

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Ol' PaulB aint on this site anymore :(

If u have serious Q's & A's let me know and I can pm u his :talk:
 
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06exc400

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Thanx Joker:

I read the whole project and found the make of the sadle bags. Thanks for the fast reply though :) :tup:
 

PaulBurke

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shoobear wrote:
Hey tell me about what u did to your forks.

I am getting the same tank and will have to adjust the forks.....

I know this is a little late but....

The stock fork spring is 4.4N/mm, I put in the 4.6N/mm. I'm about 170 lbs and ride the bike pretty hard. The 4.6 is too stiff really, and the bike is hard to get the front feeling plush now.

I had the shop do the work and change the fork seals while they were at it. Big mistake, last time they ever got to touch my bike. The new fork seals lasted about 8 hours, obviously ham-fisted on and buggered by the bike tech.

The next time I bought the seal bullet for a couple bucks and did the job myself. Forks turned out to be waaaay easier than I had thought. The seals I put in are still fine 4000+kms later. I'll be replacing them before Baja this year and renewing the bushings while I'm at it.

Cheap easy maintenace really to ensure you won't have any problems while you're on holiday!
 

PaulBurke

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06exc400 wrote:
I want a set of bags and those one look great, What Brand/Make?

Those are Wolfman Luggage bags. Eric at Wolfman makes awesome stuff, but I didn't really like these bags in the long run. I have taken them on two trips to Mexico, but realised after the first trip that it's pretty easy to put a hole in them. After they have a hole, they tend to hold water pretty well!

I pack my clothes in ZipLoc freezer bags now, and my last trip using that method worked great. I've got some new saddlebags from Motosport Panniers called DirtBagz.

438446190_vuWcF-L.jpg


This is a pic of them and the wolfman enduro tank bag on my buddy Bruce's bike. His bike was a 450, and is now a 570 I think. A fellow advrider BBriggs makes the racks that hold them on the KTM EXCs. They are kickass racks, light and tough.

FWIW, I think Eric at Wolfman is the manufacturer of the Dirt Bagz.
 

PaulBurke

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tazzman02 wrote:
Does anybody have the part number of that light/kill/horn switch thats pictured in this thread?  Does it put up with the wet? Thanks

That was the stock KTM part, and it has given up the ghost. The kill switch has failed, so I'm replacing it this weekend with another bar switch replacement from Sicass Racing. http://www.sicassracing.com


picserve.cgi


We'll see how this one lasts. Good looking kit, no kill switch though - so I have to wire that separately.
 
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06exc400

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The switch seems to be good, I am using the same one, The signals switch seems a little soft and does not have a positive feel but it all works good, There is a super bright led for the high beam that is a bit anoying but can be disabled by not using the ground wire on the harness. Anyways thats for the reply.



Rod
 

Fjr eh

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I have atwo sets of springs, for salefront and rear.

A stock set up and a set for a light rider.

I'll check into the numbers

Mark
 

PaulBurke

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Fjr eh wrote:
I have a two sets of springs, for sale front and rear.

A stock set up and a set for a light rider.

I'll check into the numbers

Mark

Like a dummy, I didn't collect my stock springs from the dealer when I had them put in the new ones....
 

PaulBurke

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06exc400 wrote:
... There is a super bright led for the high beam that is a bit anoying but can be disabled by not using the ground wire on the harness. Anyways thats for the reply.

Rod
I got mine installed today, and you're right, the LEDs are tiny but super frickin bright. If they become problematic I'll use your fix (or a black sharpie).
Nice ergonomics with this switch it seems, my "stocker" turn signal was sticky as hell from brand new.
 
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mattyktm

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PaulBurke wrote:
06exc400 wrote:
... There is a super bright led for the high beam that is a bit anoying but can be disabled by not using the ground wire on the harness. Anyways thats for the reply.

Rod
I got mine installed today, and you're right, the LEDs are tiny but super frickin bright. If they become problematic I'll use your fix (or a black sharpie).
Nice ergonomics with this switch it seems, my "stocker" turn signal was sticky as hell from brand new.


Just so you all know if you plan on going to the HID X2 light from Trail Tech, this switch does not work, nor does it free up any room to bring the clutch closer to the grip which was why I originally bought it. When you switch between high and low beam there is a short that turns the HID off completely then back on which you have to wait for it to recharge. It's a major pain in ass at night. I'm going back to stock switch so if someone wants to buy mine, it's available. I'm going to install the trail tech ON/OFF switch to keep it all off for bush riding and daytime.
Pic attached with HID light I refer too.
 

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