Katie M- my 525EXC

Mak10

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Aug 20, 2018
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Sitting around with a broken leg isn’t much fun and I have the Super Tenere pretty much farkled how I want it.

I’ve been meaning to get my KTM 525 exc out, and start putting it back into running order.

I bought the bike new in 05 after going through a nasty divorce. Love the bike, but life got busy and my time and money was needed elsewhere.

I have my Super Tenere set up how I like it for me, time to get Katie M out to complement the more serious off road.

1. Pull carb and get rebuilt,
2. Get forks rebuilt with new seals
3. Re assess what else needs fixed.320B68DC-F8E2-4A6D-A16A-7453A0E9F080.jpegD71C341E-03B1-483C-952E-C386C32A0C3E.jpegE2FC453C-E9DA-49ED-9BAF-0E5EF60DAF5C.jpeg8EA90685-CC69-4A6B-BF75-BF171EC14796.jpeg
 
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regder

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Toronno
Sweet bike, best of luck getting it back on the road/trail.

Broke my leg last year, not a fun experience.
 

Dirt_Dad

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Nice...I once had the 520 version of the EXC. Most jaw dropping powerhouse machine I've ever swung a leg over.
 

Mak10

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It just pulled apart in my hand. 4CB12863-E002-440E-9563-CD85643D6E39.jpeg
It hasn’t seen much use in 15 years. Last ridden in 2012
4ED53372-52FE-4C8A-868C-2258A46B9926.jpeg
 

ballisticexchris

Chris Moritz
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That's RFS is a great motor in that bike Mark. I was in the same boat as you in in 2007. Get a roll around stool and go at it.

Make sure you check the screw adjusters on the valves. The intake valve on the left side of the motor tightens up the soonest. Those motors are good for close to 500hrs before before you run out of adjustment.

Replace the old tires/tubes. The knobs are going to peel off if they are old. New tires are super cheap.

I'm sure there is more but you will figure it out.

Man that is a nice low hour bike!! And really nice garage!!

Was that yellow chunk of foam. . . . an air filter?
Yes an old rotted filter from bike setting.
 

Tenman

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Dec 7, 2013
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Natchez Ms USA
Sitting around with a broken leg isn’t much fun and I have the Super Tenere pretty much farkled how I want it.

I’ve been meaning to get my KTM 525 exc out, and start putting it back into running order.

I bought the bike new in 05 after going through a nasty divorce. Love the bike, but life got busy and my time and money was needed elsewhere.

I have my Super Tenere set up how I like it for me, time to get Katie M out to complement the more serious off road.

1. Pull carb and get rebuilt,
2. Get forks rebuilt with new seals
3. Re assess what else needs fixed.View attachment 70963View attachment 70964View attachment 70965View attachment 70966
Nice shop
 

ballisticexchris

Chris Moritz
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This a really nice bike you have Mark!! Not sure if you are going to re-jet it but I highly recommend the JD kit. Good news is that FCR carb is not too picky in temperature and elevation changes. I have an adjustable leak jet on mine and don’t even mess with it.
 

Mak10

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SE Idaho
My first goal is to get it running. The JD jet kit is sitting in my cart at RMC :) after I get the carb back on, I need to service the forks with new seals. They are the reason I quit riding the bike. They were leaking and something else always took my time and money. So it just sat.
I am tackling one issue at a time as to not disassemble the whole bike at once.
After I get it soundly running (shouldn’t take much) I want to do the following.
Bigger gas tank
JD jet kit
Better LED light
Fan kit (I never had a problem with it over heating before though).

It is titled and has a street plate. I need to at least add a brake light. Idaho is pretty lax on licensing. I have little intention of riding this on pavement.
 

ballisticexchris

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There is some controversy on this but I will tell you I have been running Evens waterless coolant on all my dirt bikes for years. My 300 never had a fan and the only reason I run a fan on my Beta is due to the super slow rock crawling. Zero issues on both bikes and have been north of 300 degrees.

Also in regards to suspension. The PDS needs a little more rider sag than linkage. 110-120mm. Springs are a bit pricy and I highly recommend to get proper springs for your weight. Race tech makes an outstanding progressive spring for the rear. If you are over 200lbs it will be the P30.
 

BaldKnob

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Aug 11, 2012
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Location
SENC
With the carb out, would be a good time to install the JD fuel screw. This allows you to adjust if necessary without fumbling with a stupid thumb driver or a super expensive MotionPro 90* screwdriver. Burnt hand and fingers may still occur so proceed with caution!
 

Mak10

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Aug 20, 2018
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SE Idaho
Parts showed up today,

Adjusted the valves, new needle and seat, JD jet kit installed, new battery, carb and all other items put back on and fired her up!

Riding this after only riding my Super Tenere for the last two years was quite the experience. It felt like a bicycle, so small and light.
Now I have to replace the fork seals. D8706C6E-3C44-43E6-BEF7-9D02D95BB840.jpeg
 

ballisticexchris

Chris Moritz
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Right on Mark!! I'm very happy for you. Living in Idaho have you have considered the Tour Of Idaho? You have the perfect bike for it. And just by seeing what you are able to do on the Tenere it would be an amazing ride. Think some Giant Loop stuff and Nitro Mousse inserts with some knobby's of your choice.

That ride is on my bucket list!! If I ever heal up enough to do some multi day off road sections I'm in!! Of course I would do the easy sections. Jimmy Lewis did all the hard ways and said it was brutal!!
 
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