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Old 05-14-2010, 05:41 AM   #1531
stevh0
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Joined: Sep 2007
Location: Cape Town, ZA
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My Wr450 also shoots flames on the over run.
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Old 05-14-2010, 06:39 AM   #1532
Stu
Buffo Maximus
 
Joined: Feb 2004
Location: Eastern YahooLand
Oddometer: 894
Going Smoker

"previous owner had "repaired" a crack in the water jacket with some jb weld. the fix failed and left me with a cracked cylinder. real nice. so yea fun stuff.

after this she is going up for sale and dare i say it.........two smoke time. sorry guys."

Your pix look like you really enjoyed your 540. A fun bike. My 525 is also fun and I use it differently from my '09 300 XC-W. The 525 as a DS bike or for places like Utah cannot be beat. Low vibration and great mileage plus fantastic performance (proved again with your pix).

The bored stock cylinders, if not done carefully, can crack since they are thinner. That is why KTM has a different cylinder for their 540 kit. If I go the 540 route I'll get the KTM cylinder, toss their piston, and have Dave (DJH) set the head up correctly & send me the domed piston. Expensive, but the correct way to do it.

Why don't you keep the 540 (or now back to 525?) AND get a 2-stroke?

Stu
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Old 05-14-2010, 06:49 AM   #1533
lamoson
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Quote:
Originally Posted by Stu

Why don't you keep the 540 (or now back to 525?) AND get a 2-stroke?

Stu
oh man, if that was in my budget i would do it in a heartbeat. i do REALLY love this bike. but for the riding i do, woods, trails, and some track, i think the 250 or 300 is more fun. we will see how i like the 540 again, it has been a month since i have ridden. but the ease of maint and cost of parts for the two stroke is a VERY nice draw.
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Old 05-14-2010, 06:59 AM   #1534
marum017
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Quote:
Originally Posted by LukasM
That would be an aweful lot of work. The SMR swingarm is the same as the 05-07 EXC ones. All 04+ swingarms have a 17mm pivot, yours is still 15mm. This means you would have to bore the engine cases, which would be have to be done outside the frame. Best with the cases split. Hardly worth it.
I'm not familiar with all the differences, but couldn't you re-use the 15mm swingarm bolt and have a couple of collars machined to step up the diameter to 17mm for the bearing area? The biggest issue would be this acting like a bushing on the bolt (harder bolt, collar wears; harder coller; bolt wears).
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Old 05-14-2010, 07:49 AM   #1535
Stu
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Joined: Feb 2004
Location: Eastern YahooLand
Oddometer: 894
Costs

Quote:
Originally Posted by lamoson
oh man, if that was in my budget i would do it in a heartbeat. i do REALLY love this bike. but for the riding i do, woods, trails, and some track, i think the 250 or 300 is more fun. we will see how i like the 540 again, it has been a month since i have ridden. but the ease of maint and cost of parts for the two stroke is a VERY nice draw.
You are right. I mostly ride my 300 around here (woods stuff) and use the 525 for DS and travel (UT & CO). Repairing 4-strokes that are raced is expensive. I thought about the 320 kitted 250 but, hey, my piston kit for my 300 is only about $420. And, I still don't need one.

If you get a woods weapon consider the 250 XC rather than the XC-W. The 250 is really snappy and the gearing is great for the tight stuff on the 250. You will still be able to do 50-55 in the open areas.

If you want to go faster get the 300 XC-W and mill the head (but not so much that you need race fuel) and you will be able to keep up with the 4-strokes in the open stuff and it will pull 14/52 gearing and still zip in the tight stuff.

Just don't take a 2-stroke to Moab on longer trails. The vibration and poor mileage compared to the 525/540 will really get to you. They are great on rose garden hill or top of the world, though.

Stu
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Old 05-15-2010, 08:18 AM   #1536
Stu
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Joined: Feb 2004
Location: Eastern YahooLand
Oddometer: 894
KTM Oil Screen Bolt Removal

Here is the way that works for me:

1) Standard hex bolt: lean or lay the bike over, fit the 8mm hex socket in the head, attach a hand impact driver on it (I use the Snap-On one since it has a lot of mass) and tap it sharply with a heavy hammer (I use a hand drilling hammer). One blow should do it and start the bolt. Replace it with the standard 13mm bolt. An inmate makes one from billet and sells it. It is the best. Cycle Hutt sells one: http://www.ktmcyclehutt.com/ktm-part...tment=bigbikes

2) Aftermarket 13mm bolt: The only socket I can get in there is the Snap-On 13mm for 1/4" drive. It is thin enough to go in. Otherwise you will have to grind some material off the head of some other socket in order to get it to fit between the bolt and the case recesses.

Stu
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Old 05-15-2010, 09:00 AM   #1537
LukasM
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Location: On a RTW ride - currently Central Asia
Oddometer: 5,335
Quote:
Originally Posted by Yooper-at-heart
Thank you very much. You are the man!
Didn't you say star shaped? I know that KTM makes a replacement bolt with a female torx head. Is that what you have?
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Old 05-16-2010, 06:28 PM   #1538
Stu
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Star VS 6-point

The one I got from the guy in Colorado is 6 sided. So is the more expensive, but worthy, PRD: http://www.ktm-parts.com/mm5/merchan...ct_Code=PRDRFS.

Check it out. I think they are all 6 sided.

Stu
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Old 05-17-2010, 12:22 AM   #1539
LukasM
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Location: On a RTW ride - currently Central Asia
Oddometer: 5,335
Quote:
Originally Posted by Stu
The one I got from the guy in Colorado is 6 sided. So is the more expensive, but worthy, PRD: http://www.ktm-parts.com/mm5/merchan...ct_Code=PRDRFS.

Check it out. I think they are all 6 sided.

Stu
Hi Stu,

The new version of the bolt takes a female torx instead of an allen key for sure, it's a T45 (as per Kev in Yorks). I haven't seen one up close so maybe it has a hex head also?

77038017000 SCREW PLUG


I went with the very nice PRD kit myself, got it from a special on Ktmtalk.

Lukas
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Old 05-17-2010, 01:41 AM   #1540
spaceman_spiff
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Joined: Jul 2008
Location: Santa Cruz, CA
Oddometer: 294
Quote:
Originally Posted by marum017
I'm not familiar with all the differences, but couldn't you re-use the 15mm swingarm bolt and have a couple of collars machined to step up the diameter to 17mm for the bearing area? The biggest issue would be this acting like a bushing on the bolt (harder bolt, collar wears; harder coller; bolt wears).

sleeves wouldn't be too bad... Hmmm... Do you know what the differences would be? Length and width etc?
Thanks guys!
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Old 05-17-2010, 06:46 PM   #1541
greengoose
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Joined: Dec 2004
Location: Salt Lake City
Oddometer: 3
If anyone is looking for some 525 goodies I am parting out my 04

http://www.advrider.com/forums/showthread.php?t=580317
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Old 05-17-2010, 09:20 PM   #1542
spaceman_spiff
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Location: Santa Cruz, CA
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anyone know if I can run an 04+ exhaust system on my 2003?
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Old 05-18-2010, 12:41 AM   #1543
LukasM
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Joined: Nov 2006
Location: On a RTW ride - currently Central Asia
Oddometer: 5,335
Quote:
Originally Posted by spaceman_spiff
anyone know if I can run an 04+ exhaust system on my 2003?
Yup. You also need to use the newer header flange, though.
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Old 05-18-2010, 05:37 AM   #1544
ThumperDRZ
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Joined: Sep 2005
Location: Stinkin' County, MO
Oddometer: 2,399
Quote:
Originally Posted by spaceman_spiff
anyone know if I can run an 04+ exhaust system on my 2003?
Nobody I have found makes a header pipe guard for the '03 because of the dual pipes....I will probably buy the Flatland and cut it at various points to reform it. I'll then have one of the fellas here at work reweld it into it's new shape though spanning both pipes completely is probably impossible. At least if I raise the modified guard up with standoffs, I'll be able to get the majority of the pipes covered...and not cooking my pants or leg if (when) I should fall......

Compared to my DRZ - these engines put out a tremendous amount of heat - trying to decide if the RLR overflow tank and fan are necessary.....
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Old 05-18-2010, 07:41 AM   #1545
fuzzydude2
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Location: Phoenix, Az
Oddometer: 211
cooling fan with a IMS tank

I have an 2005 525EXC will, the cooling fan work with the IMS tank?
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