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Old 06-22-2013, 12:08 PM   #1
HellSickle OP
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Converting 450 RFS to 520, 525?

Since my 2006 450 EXC will be due for a top end this winter, I'm thinking of bumping the cc's to help fill my gap for a mid range dual sport.

Which 5xx shared the same motor? Pretty sure it's just a difference in bore, right?

For those that have made the conversion, how did it change the engine characteristic? More or less low end? How about fuel economy? Did you need to tweak jetting, if so, can you just rely on the KTM 525 jetting table?

I'm plagued with the RFS creeping intake valve issue. They need adjusting every 700-800 miles (or sooner). Any recommendations for aftermarket valves that won't have this issue?

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HellSickle screwed with this post 06-22-2013 at 12:16 PM
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Old 06-22-2013, 12:40 PM   #2
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Quote:
Originally Posted by HellSickle View Post
Since my 2006 450 EXC will be due for a top end this winter, I'm thinking of bumping the cc's to help fill my gap for a mid range dual sport.

Which 5xx shared the same motor? Pretty sure it's just a difference in bore, right?

For those that have made the conversion, how did it change the engine characteristic? More or less low end? How about fuel economy? Did you need to tweak jetting, if so, can you just rely on the KTM 525 jetting table?

I'm plagued with the RFS creeping intake valve issue. They need adjusting every 700-800 miles (or sooner). Any recommendations for aftermarket valves that won't have this issue?


Kibblewhite valves = no more valve adjustment. (ok, exaggeration. But close)

My 525 is now a 560, and has been a 540. It has a cam, 40 mm carb, etc.

If I had to do it all over again, I probably would stay stock. Bike is far more difficult to manage in tight singletrack, but really brings the power on HARD- that's the fun part.

KTMtalk.com will provide far more answers about this. Look for CAFLASH's posts (people love to hate him, but he's a good guy) or the guy in Washington who's name escapes me right now- good guy, bored my carb and built two friend's bikes.
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Old 06-22-2013, 03:42 PM   #3
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DJH is the guy from Washington.

Travis Smith is ThumperRacing and cam make your 450 into a 570 and do head work too plus supply a cam to suit.
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Old 06-22-2013, 07:21 PM   #4
renogeorge
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520 and 525 EXCs are the same bore and stroke. Just a marketing change. 530 is a completely different motor--starting in 07 for the SX '08 for the other models. 525 barrel and piston bolt right up.

I prefer the 525 if you are going with an EXC. If a lighter crank/flywheel XC or SX, the 450s are fun. Just depends what you ride and what you are looking for. For me, frequent dual sport generally leads me to the big bore.

525 is no harder to jet than 450. Get the right needle and the AP squirt right and the rest is pretty easy. As suggested try the RFS section in KTM Talk.

FWIW
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Old 06-22-2013, 07:56 PM   #5
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Jeff...ping StmbtDave - his 450RFS is now a 540 IIRC.
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Old 06-23-2013, 11:34 AM   #6
HellSickle OP
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Thanks guys. I will go with the 520 and stock cam and carb. IMO going any bigger and messing with the cam starts to impact reliabilty.
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Old 06-23-2013, 06:29 PM   #7
wvridgerider
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I have a 525 and I hope to get this summer out of the top end. I was thinking of doing the 540 kit from thumper racing.
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Old 06-23-2013, 07:50 PM   #8
jar944
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Quote:
Originally Posted by HellSickle View Post
Thanks guys. I will go with the 520 and stock cam and carb. IMO going any bigger and messing with the cam starts to impact reliabilty.
Up to 570 (really 555cc) is reliable as stock. The 525 cylinder would be the cheapest option.
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Old 06-24-2013, 10:29 AM   #9
HellSickle OP
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I just priced pistons for 450 vs 525. Sweet Jeebus! The 525 piston is 2X the cost ($400 vs. $200). Price of cylinder + piston is only about a $100 differential. If the current cylinder looks good, I may put off this project & just update the valves.
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Old 06-24-2013, 11:19 AM   #10
LukasM
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Look into the KTM Hard PArts 540 kit, you should be able to get a nice discount on it and it's very good quality.

Otherwise look into the Thumper Racing kits that use CP pistons, or the Wossner piston kits that DJH supplies.
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