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Old 01-18-2015, 02:44 PM   #1
Night Falcon OP
Adventure NZL
 
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Joined: Dec 2008
Location: New Zealand
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My EXC530 Adventure

It wasn't on my Bucket list to build an adventure bike in 2015 but I have to say I'm quietly looking forward to tinkering with the 530 . The plan is to keep it as light and nimble as possible, to maintain its "Enduro-ness", but also enable it (and me) to better cope with the longer saddle time needed to disappear for a day or two's exploring.

So to begin, here she is, a stock (almost) 2010 KTM EXC530.



Planned work includes:

Fit an HT Racing oil cooler
15l Safari Tank
Cush Drive rear wheel
Improve the seat
Build and fit a PVC tool tube
Fit a windscreen
New tires
Tidy up the rear end wiring - flush mount indicators installed by PO
Bar risers
Fit GPS
Better front lighting - don't know how they pass a WOF with the stock headlight.
Fit Tank Bag
Fit decent hand guards
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Old 01-18-2015, 02:45 PM   #2
kiwipeet
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Nice :)
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Old 01-18-2015, 03:07 PM   #3
Box'a'bits
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Nice. How's the rehab coming along Marty? Are you fully active again, or this a short term something to meet longer term goals - something to keep the boredom at bay for a while.
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Old 01-18-2015, 03:25 PM   #4
Night Falcon OP
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Quote:
Originally Posted by Box'a'bits View Post
Nice. How's the rehab coming along Marty? Are you fully active again, or this a short term something to meet longer term goals - something to keep the boredom at bay for a while.
Gidday Steve. Going into surgery on 2 Feb to have repair work on my shoulder - torn cartridge, tendons, and remove some bone to help it heal. Surgeon expects it will be end of April before I'm able to enter the ring again.

They told me it would be at least 18months recovery after the crash and it seems they might have known what they were talking about...even so I still struggle with it, so yup...this project will be a nice distraction and incentive to handle another 3 months of recovery and physio
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Old 01-18-2015, 04:29 PM   #5
Night Falcon OP
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HTR cooler just arrived 7 days from the US. Paid GST for the Safari tank yesterday so that should be through customs to me this week as well....it all exciting

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Old 01-18-2015, 04:39 PM   #6
Mark_S
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Location: Kapiti NZ
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18 months.....

that’s just so so long





remember lots of photos of shiny things....
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Old 01-19-2015, 12:54 AM   #7
pampaX
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well at least is recovery, nice bike and project
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Old 01-19-2015, 04:02 PM   #8
tpbftw
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Hey ..

Cool thread, congrats on the project, will keep you busy while you're recovering! Having just been through the same exercise with a 2008 530EXC I thought I'd give you some more ideas to help lighten your wallet ;)

Very interested to see how you go with the oil cooler, have toyed with that idea too. Currently carry a 300ml drink bottle of oil with me on two-day trips to top it up if needed, then swap for 600ml fresh oil when I get home.

I use my bike for everything, trail riding, adv riding, 500km roadie trips, and commuting 80+km per week. Pretty happy with it after doing the below mods:

JD Jet Kit with AP o-ring mod
- best mod, huge performance and responsiveness improvement, easy as to install just follow instructions and use recommended settings. You don't even need to remove the carb from the bike to fit.
- http://www.mainjet.com.au/product_in...bbb665be6e0a03

Dirt Tricks Cam Chain Tensioner
- The OEM CCT is well known to be noisey, the previous owner had replaced with 2011 OEM CCT which still slapped at low rpm
- http://dirttricks.com/shop/ktm-timing-chain-tensioner

Trailtech High output stator
- If you add a fan, this is a must do. I have wired all my accessories to run directly from the stator so no risk of running the battery flat.
- http://www.trailtech.net/stators-fly...stroke/sr-8313

2x Spa waterproof fans on manual switch
- OEM fan kit for right side radiator (previous owner)
- Second fan off Amazon - exact same model, much cheaper than OEM kit, mounted to left radiator. Useful for 40*C Melbourne days in traffic but one fan would probably be heaps for NZ.
- http://www.amazon.com/dp/B009OBP55G/...190_TE_3p_dp_2

EarthX battery
- Twice the cranking power and half the weight of the OEM battery
- http://www.ebay.com/itm/EarthX-Lithi...407c39&vxp=mtr

17 litre Safari tank
- around 300km range

Doubletake mirrors
- Easily fold out of the way when trail riding
- http://sicassracing.com/store/produc...bletake_mirror

Rear carry rack
- www.nomadic-racks.com

15t 48t gearing, 4700rpm @ 100kph on Trailtech rev counter
- gearing is just low enough for trail riding but can easily swap to 14t front without swaping chains

Generic USB outlet to charge smartphone (GPS)

QuadLock handlebar mount for smartphone (GPS)
- http://www.quadlockcase.com/products/bike-mount

Hema offroad maps for Android
- download maps for offline use

45/40w S2 Halogen KTM Upgrade Bulb
- Super bright and much cheaper than a whole new headlight
- http://sicassracing.com/store/bulbs/...m_upgrade_bulb

Flushmount rear indicators
- http://sicassracing.com/store/turn_s...flat_mount_ktm

Ignition Key switch
Was quite suprised they don't have one factory, not that it will prevent someone who really wants to take it but it helps me sleep at night
- http://sicassracing.com/store/produc...?reviews_id=50

Rear tail removed, numberplate relocated up

Reusable Stainless steel reusable Oil filter
- http://www.onlineracingspares.com.au...xc/OFS-5003-00


Enjoy the build, look forward to your updates
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Old 01-19-2015, 08:34 PM   #9
wairau
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Joined: Mar 2011
Location: bay of plenty, nz
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where did you get that bike mr falcon? dont remember seeing it on tardme?

looking fwd to reading about your mods to it
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Old 01-19-2015, 10:28 PM   #10
CrazyFrog
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Location: Nelson, NZ
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I'm running a slightly modified (improved) 07 525 EXC.
I wouldn't bother with cooling fan kit for general ADV use and trail rides. Especially if you're fitting the oil cooler. The fans are good if you're always in the desert or revving the hell out of the bike on muddy trail rides or slow riding. My EXC has only boiled once in 250hrs, that was in middle of a slippery ride in the bush when I was crawling along wheel spinning.
I use a sealed catch bottle instead, which suck any fluid back into radiators.

The oil cooler will be great for extending oil services out to 20-30 hours instead of 15hrs, basically double your normal oil capacity. ADV riding is pretty easy on engine/oil temps anyway, as you get loads of cooling going on at road speeds, riding normally, not raping the top end like Toby Price would.

Get a Seat Concepts USA seat rebuild kit, uses your existing seat pan, and you just staple new seat cover/foam to it. Wider seat is the answer, not neccessarily softer.

For travels, I use Wolfman E12 saddlebags, Wolfman enduro tank bag, and front fender bag for tools.

I use standard RAM mount for my Garmin 60CSX, works perfectly with no vibes, and have hardwired GPS to the battery.

Definitley use the shorter plate holder, the long ones vibrate like hell and end up breaking, and when you mount indicators, make sure they're out of the firing line of the exhaust, My Akrapovic has destroyed 2 indicators before I repositioned them.

I also use 40/45W headlight bulb, better but still ot great. It's the stock reflector which is shit, so brighter bulb isn't best answer. I don't do a lot of night riding though, so haven't bothered upgrading. I've considered 12v LED auxillary lamps to give lighting a boost.

Gearing: Run 15/45 for general road/adv work, you only want 48T if your doing slow riding. Easy to change to 14/48 for trails.
Make sure you use a clutch slave case protector too, money well spent when I broke a chain riding in the sand dunes.

I got a used cush hub rear wheel from a LC4 being parted out. Fits with no mods and just uses different bearings from stock enduro wheel. Highly recommended

Recommend going up to .44 fork springs, the stock .42 ones are a bit light.

Ummm, I think that's about it for now from me.

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Old 01-20-2015, 01:06 AM   #11
Night Falcon OP
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Thanks guys for the tips and advice, very much appreciated. Seat concepts is the one I've been looking at and I hear they are pretty good. The cush drive is the next item on the agenda, am looking pretty hard at these http://www.ebay.com/itm/KTM-CUSH-DRI...672291?vxp=mtr

Finished building my tool tube today so will fit it tomorrow - pretty pleased how its turned out.

I don't need to worry about melting indicators with these suckers




Quote:
Originally Posted by wairau View Post
where did you get that bike mr falcon? dont remember seeing it on tardme?

looking fwd to reading about your mods to it
It was on TM but not for long as I swooped pretty quickly - 82hrs and way cheaper than those ones Boyds have on there
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Old 01-20-2015, 01:14 AM   #12
wairau
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yes, seeing this thread i did check to see if they were both still there...

nicely done
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Old 01-20-2015, 01:46 AM   #13
CrazyFrog
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Location: Nelson, NZ
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Quote:
Originally Posted by Night Falcon View Post
T

It was on TM but not for long as I swooped pretty quickly - 82hrs and way cheaper than those ones Boyds have on there
I'm guessing that's the bike that sold for around $6.5K in early Dec or did someone else get that one? Nice score either way.

I'm keen on seeing the tool tube pics too and where you end up mounting it on the bike.
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Old 01-20-2015, 12:31 PM   #14
Eddieb
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Location: The Tron, New Zealand
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Quote:
Originally Posted by Night Falcon View Post
Thanks guys for the tips and advice, very much appreciated. Seat concepts is the one I've been looking at and I hear they are pretty good.
I bought a seat concepts for the DR, didn't like it and when I sold another DR I also had at the time the seat concepts went with that and I kept the home made seat that originally came on the 2nd bike.

YMMV of course.
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Old 01-20-2015, 09:05 PM   #15
Night Falcon OP
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Buying seats based on someone else's recommendation can be a bit hit and miss but fortunately for me I know a local bloke with a 530 that has a seat concepts attached so my plan is to try before I buy. but meanwhile......


A welcomed Aussie import arrived this morning



Tool Tube fitted



that's one fine lookin hiney.... if I do say so myself

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