Ktm 525 set up
- Thread starter Dirtnut67
- Start date
U
UPsnowbiker
Well-known member
What year?
U
UPsnowbiker
Well-known member
I've got a 2010 450 XCw but close enough(carbed). This will be my third year on one and There's a solid group of us up in the U.P. now. PM me and I'll just give you my number, we can run down the list of things to do and stuff I've learned. Happy to help out another Michigan guy.
U
UPsnowbiker
Well-known member
Keep in mind I have a 2010 XCW but Yooper01 just built up an older RFS and would have some tips as well.
Must do:
-Route all carb breather lines underneath the gas tank. This will stop them from icing up.
-Get a JD jet kit and rejet appropriately
-Keep as much snow of the carb as possible. I used thin plastic sheeting and just zip tied in the panels inside open spots in the frame. Sure snow will still get in but this will help a lot. I could text you some pics of what we do.
-Block the face of one of your radiators. I have one that goes on with plastic push rivets.
-My bike had a thermostat that would open a valve from the radiator when the engine got hot. (my tech terminology may be off). It would not open in the winter because it was so cold, my engine started to overheat and spit oil out of the head gasket. My dealer removed the thermostat and this has never been an issue again.
By doing everything above I was able to ride problem free the last 2 seasons. When it's sub zero it may run a little off at the end of the day but still doable. There is a lot of talk of carb heaters and temp gauges, maybe I should be doing that but seems good so far.
Should do:
I'm not sure how the mototrax is but everyone agrees heavier form springs is a good idea. I have the TS with TSS and I think that helps not need as heavy of springs. I put in the correct springs for my weight(225) and it works fine. I jump a little and it could use some extra then but no big deal.
Nice to have:
-Heated grips
-large pegs
-risers
-LED light bar(I went overboard here) Cyclops makes an LED bulb for the stocks light that is pretty cheap and works really well.
Must do:
-Route all carb breather lines underneath the gas tank. This will stop them from icing up.
-Get a JD jet kit and rejet appropriately
-Keep as much snow of the carb as possible. I used thin plastic sheeting and just zip tied in the panels inside open spots in the frame. Sure snow will still get in but this will help a lot. I could text you some pics of what we do.
-Block the face of one of your radiators. I have one that goes on with plastic push rivets.
-My bike had a thermostat that would open a valve from the radiator when the engine got hot. (my tech terminology may be off). It would not open in the winter because it was so cold, my engine started to overheat and spit oil out of the head gasket. My dealer removed the thermostat and this has never been an issue again.
By doing everything above I was able to ride problem free the last 2 seasons. When it's sub zero it may run a little off at the end of the day but still doable. There is a lot of talk of carb heaters and temp gauges, maybe I should be doing that but seems good so far.
Should do:
I'm not sure how the mototrax is but everyone agrees heavier form springs is a good idea. I have the TS with TSS and I think that helps not need as heavy of springs. I put in the correct springs for my weight(225) and it works fine. I jump a little and it could use some extra then but no big deal.
Nice to have:
-Heated grips
-large pegs
-risers
-LED light bar(I went overboard here) Cyclops makes an LED bulb for the stocks light that is pretty cheap and works really well.
Last edited:
all good suggestions on the KTM.
On the 2005 vintage KTM carb models we found the most usefull addition was wrapping the head pipe back to the muffler. When the KTM was icing the carb riding in 6" of fresh snow on a trail, I rode alongside and observed snow from the ski hitting the hot unwrapped pipe and flying back as freezing water and icing up everthing on the ride side of the exc. Just stuffing a rag in next to the carb on the right side let the carb run enough warmer that the internal carb ice was not a problem. After than we ran good pipe wrap and a plastic deflector behind the pipe covering the right side of the carb, three years never iced with that set up.
On the 2005 vintage KTM carb models we found the most usefull addition was wrapping the head pipe back to the muffler. When the KTM was icing the carb riding in 6" of fresh snow on a trail, I rode alongside and observed snow from the ski hitting the hot unwrapped pipe and flying back as freezing water and icing up everthing on the ride side of the exc. Just stuffing a rag in next to the carb on the right side let the carb run enough warmer that the internal carb ice was not a problem. After than we ran good pipe wrap and a plastic deflector behind the pipe covering the right side of the carb, three years never iced with that set up.
4th season on mine its a 05 sx with the mxc gearbox. all I do is run carburetor vent hoses down by the sprocket. Get a fan the 525 has no problem making heat. When you get in the steep even on powder days she will get hot. Temp never gets below 135. As far as airbox all I do is run a stock filter no oil with the filter skin and airbox cover off. Have never had a carb ice problem ever. If carburetor hoses get blocked it acts like its gonna die when you let off.
Tips for the 525
I've got a 06 with a 15 SX120 kit on it. Which believe me was a giant pain to get setup to fit the 3rd shock on this bike and make the pivot work.
Things to look for if you are running a TSS or SX kit 15 or older:
The chain tension blot will hit subframe on shock compression. I moved to an allen key and run the stopper nut below the block.
Airbox has to come out for the strut rod to work on the PDS side mount. I bought an extra and cut only the battery mount to remain on the bike.
2.25 to 3" silicone adapter to 3" x 6" long aluminum tube with holes drilled into it the whole way as a pre-filter holder works much better as an air intake.
jetting: JD kit, red needle, likely you will need a 45 pilot, ~180 main, needle in middle clip and be good for 4-8k feet. I'm running the R&D float bowl with adjustable leak jet also.
Replace the garbage stock thermostat with a thermobob, get a Y hose for the top of it, I used a 250SX hose kit off ebay to get the Y I needed for this. This will run cooler in summer also (better flow). The HBFE kit is the right one for this bike, order any 129 dollar kit and add HBFE to special instructions on checkout. it's not officially on the website yet.
Get an engine snow jacket to keep the snow off... in powder it will drop the engine to the 90s easily without one. I built mine form plastic.
I header wrap the pipe all the way back to the silencer, the coat with silicone header wrap paint to waterproof it then I added a moose carbon guard to keep it from getting torn in the trees.
Let me know if you need pics or anything else.
I've got a 06 with a 15 SX120 kit on it. Which believe me was a giant pain to get setup to fit the 3rd shock on this bike and make the pivot work.
Things to look for if you are running a TSS or SX kit 15 or older:
The chain tension blot will hit subframe on shock compression. I moved to an allen key and run the stopper nut below the block.
Airbox has to come out for the strut rod to work on the PDS side mount. I bought an extra and cut only the battery mount to remain on the bike.
2.25 to 3" silicone adapter to 3" x 6" long aluminum tube with holes drilled into it the whole way as a pre-filter holder works much better as an air intake.
jetting: JD kit, red needle, likely you will need a 45 pilot, ~180 main, needle in middle clip and be good for 4-8k feet. I'm running the R&D float bowl with adjustable leak jet also.
Replace the garbage stock thermostat with a thermobob, get a Y hose for the top of it, I used a 250SX hose kit off ebay to get the Y I needed for this. This will run cooler in summer also (better flow). The HBFE kit is the right one for this bike, order any 129 dollar kit and add HBFE to special instructions on checkout. it's not officially on the website yet.
Get an engine snow jacket to keep the snow off... in powder it will drop the engine to the 90s easily without one. I built mine form plastic.
I header wrap the pipe all the way back to the silencer, the coat with silicone header wrap paint to waterproof it then I added a moose carbon guard to keep it from getting torn in the trees.
Let me know if you need pics or anything else.
525 with moto-traxx opinion
Well I was able to ride about 20 miles today on groomed trail and woods. Now our snow conditions are not the greatest. About 3" of hard pack and 2 to 3 powder on top. With that being said. I did not care for the groom trail riding. The front would follow every groove there was from snowmobiles. I'm not say it was terrible just not my favorite. Off the groom trail? It was awesome. I was even in the tight woods with branches and trees glancing off the bark busters. I even used a few trees to glance off with the ski. I will be interested if I can make adjustment to improve groom trail riding. Is almost as if the middle carbide on the ski is too aggressive. I also think this might improve when we get more snow or more base. My 06 525 exc ran flawlessly. I put one of those radiator cap/thermostat on my bike and it ran a steady 150 to 165. I did wrap the header/ skid plate/ some plastic around the front and side of the motor to keep some of the snow out. Using a moto-traxx enduro. Some jetting changes use information oem jets. Don't remember what I put in right now. I have it written down. Stock air filter. So far I like it. Anxious for more snow and more woods riding. I think the majority of these snowbike are riddin in the mountains. Some of use eastern riders are very fortunate. We don't have the loss of power due to altitude. So we are able to use almost 100% of our bikes power. These snowbikes open up all the woods riding that we are able to ride during the summer months. Well I'm excited to start a new addiction. Let's ride!!!!
Well I was able to ride about 20 miles today on groomed trail and woods. Now our snow conditions are not the greatest. About 3" of hard pack and 2 to 3 powder on top. With that being said. I did not care for the groom trail riding. The front would follow every groove there was from snowmobiles. I'm not say it was terrible just not my favorite. Off the groom trail? It was awesome. I was even in the tight woods with branches and trees glancing off the bark busters. I even used a few trees to glance off with the ski. I will be interested if I can make adjustment to improve groom trail riding. Is almost as if the middle carbide on the ski is too aggressive. I also think this might improve when we get more snow or more base. My 06 525 exc ran flawlessly. I put one of those radiator cap/thermostat on my bike and it ran a steady 150 to 165. I did wrap the header/ skid plate/ some plastic around the front and side of the motor to keep some of the snow out. Using a moto-traxx enduro. Some jetting changes use information oem jets. Don't remember what I put in right now. I have it written down. Stock air filter. So far I like it. Anxious for more snow and more woods riding. I think the majority of these snowbike are riddin in the mountains. Some of use eastern riders are very fortunate. We don't have the loss of power due to altitude. So we are able to use almost 100% of our bikes power. These snowbikes open up all the woods riding that we are able to ride during the summer months. Well I'm excited to start a new addiction. Let's ride!!!!
I'm setting up 2 bikes similar to yours and would like to see your setup, particularly the air intake you fabricated. Thanks!
Thanks a lot. Looking for ideas. Guess I'll be removing most of the airbox
Honestly wouldn't do it. Have seen issues of snow coming through those filter pods and damaging the back of the piston. Timbersled filter skin over stock filter with airbox cover off. Really simple have been doing for 4seasons no issues, no money spent.
