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Old 12-22-2013, 02:21 PM   #1
wilso122 OP
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Ooops another 525 rally bike, one day..

Damn gone and done it again, got bored and thought whats next... after looking round ebay for a while thinking don't do it! I've only gone and bought an old 525 exc 2003. I love the RFS engine for its simple easy to maintain bulletproofness and always regretted selling the 450. It has only done 109 hours about 2200 mile and is in "ok" condition.

So I've got a little project to strip it back to nothing and build it up as a rally lite bike.

So far only really done bigger bikes, the transalp was fun putting WP suspension on the front and taking some weight off it made it a pretty capable bike


I still have wet dreams over my SE which is just an immense machine and will never be sold



Enough of that, here is the new to me weapon, got her for a good price. It is going to take me some time to finish it as it will be done as and when funds allow and this will be a strip down and rebuild starting with the frame being blasted and powder coated.


To be fair it is nothing new and has all been done before and is all well documented here in some really great posts, so if anyone is interested I will try and document the lot from the trip down to the re-build with all costs, links to suppliers, trials and tribulations, highs and lows. its probably going to take quite a few months, new baby in the house means funds are a little stretched, so along the way if you know of any second hand bits that might be of interest just hollla

One more

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Old 12-22-2013, 02:27 PM   #2
wilso122 OP
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This is the thinking before I get too far.....

Strip down
Powder coat frame
sonic clean carb, clean engine check over valves oils
strip regrease or replace all bearings
Sort out wiring and incase in wire protection
Oil cooler (ht ouch expensive!) not sure which one or bespoke build
Steering damper
Rally fairing
13l tank
rally exhaust, low slung
rear tanks if funds allow.
fan kit and bypass hoses.

Will transfer roadbook and ico from the SE.

Any way here's hoping
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Old 12-22-2013, 06:52 PM   #3
Mudguts
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Been there built that , if you need any advise feel free
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Old 12-22-2013, 10:45 PM   #4
Foot dragger
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There's one like that for sale cheap around here,hhhhmmmmmmmmm
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Old 12-23-2013, 01:29 PM   #5
wilso122 OP
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Been there built that , if you need any advise feel free
Thanks for that know your thread very well. Still not sure is I'm going rsconcepts or Alberto do tori, I do know meca systems is out not got the spondoolies for that. If it is rs might got for evo 1 kit as the bike is older it will complete that old school rally look with the bug eyes. Also gone for the 13litre over the 16l.

Cheers
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Old 12-23-2013, 01:30 PM   #6
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There's one like that for sale cheap around here,hhhhmmmmmmmmm
Do it ;)
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Old 12-24-2013, 11:57 PM   #7
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meca all the way
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Old 12-25-2013, 07:57 AM   #8
Foot dragger
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I keep hearing the RFS engines are tough cookies right back to the 1st ones built,I like the screw and locknut valve adjusters.

There's an 06 450 for sale as well as the 03 525,Im told there isnt much difference at all inside the engines? I just cant see ponying up 10+ grand for the latest greatest zippidy-doo-day vunder bikes.
The 525 guy has no idea how many hours are on his bike,the 06 450 has 118 hours and looks it,pretty clean.
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Old 12-25-2013, 03:24 PM   #9
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meca all the way
How did I know you would say that Happy Christmas, hope yer well mate.

Quote:
Originally Posted by Foot dragger View Post
I keep hearing the RFS engines are tough cookies right back to the 1st ones built,I like the screw and locknut valve adjusters.

There's an 06 450 for sale as well as the 03 525,Im told there isnt much difference at all inside the engines? I just cant see ponying up 10+ grand for the latest greatest zippidy-doo-day vunder bikes.
The 525 guy has no idea how many hours are on his bike,the 06 450 has 118 hours and looks it,pretty clean.
With the rfs so long as it doesn't smoke through the range or jump gears your pretty much good. Rfs engine is dead easy to maintain, everything else can be maintained or replaced if the price is right. Might throw the 540 big bore on it as well. Not 100% sure but I think all rfs engines are the same workings just different bores, carberation, gears.
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Old 12-25-2013, 03:49 PM   #10
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Congrats on the new bike Jez
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Old 12-29-2013, 10:40 PM   #11
707redwoodrider
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im interested

i have a 04 525 and think its great, for me. my racing days are over and as for bang for the buck the rfs bikes are great,tons of power and streetable which rules in my area . imo..post progress please
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Old 01-06-2014, 03:23 PM   #12
wilso122 OP
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Congrats on the new bike Jez
Hey big man how are you mate? Looked like a good season for you last year. Might have a wee shopping list for you once I've saved a few more quid...

Managed to get an hour on the bike today so the strip down has started...



Hopefully steal another hour tomorrow
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Old 01-06-2014, 06:30 PM   #13
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Spot on

Shout when you're ready, will sort you out no problem
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Old 01-21-2014, 02:23 PM   #14
wilso122 OP
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Cheers mike will do.

So it's turning turning into a misson! Just goes to show the importance of stripping down an old bike... For some reason there is copper slip on the head bearings and the rear axle nut is so tight I've bent me spanner trying to get it off.

The shopping list is growing by the minute, think this one will take a while and now I'm thinking go the whole hog and out a 540 bore kit on, re-valve and get the suspension properly reconditioned.....

Still Santa was generous, with a Ktm power parts voucher and buying my own stuff a new seat, tank and cooling fan arrived last week thanks to bikers jersey for sorting me out as well. Top bunch.

The bike in bits..



Copper slip on the head bearings....



Bent spanner

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Old 01-21-2014, 02:29 PM   #15
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did you try some heat?...
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