I purchased my 2006 KTM in August with big dreams of leaving my buddies in the dust. This bike boasted of being -Ready to Race-.
At first ride I was in love with the power. Any adrenaline junky would do the same. After putting about 40 miles on this bike I was very happy with my purchase.
At 80 miles my tone changed very rapidly. The bike blew a water pump seal and had to go to the shop. After a very long wait to get the silicone dripping bike returned to me, I found yet another problem. After another 10 miles or so the cir-clip (on the piston) came off which allowed the wrist pen to back out and destroy the top end. I once more returned the bike to a different KTM shop to get this repaired.
I changed bike shops due to the fact that the last one had pumped my tank dry and failed to refill the gas tank, and on top of that he shop manager was extremely short with me. At the second shop a total engine rebuild had to be performed. When I arrived to pick up my -Brand New- bike I had found that the KTM Certified mechanic had done a very poor job of taking care of the finish of my bike and had scarred up many of the engine components as well as the handle bars. My bike was covered with grease and left over engine oil. KTM did cover the rebuild, but I had to pay for all the associated fluids and filters (Over $100).
On my return home I found that the center gasket was leaking profusely so I made a return trip to the -Scratch It and Ding It Doctors-. They tore the engine down once more and patched it back together.
After a third return home, I found that all the engine oil had mysteriously disappeared.
On the fourth return to the shop, the bike required the other water pump seal (oil side this time) to be replaced.
I have had nothing but trouble out of this bike. I do not recommend KTM to anyone, and if you do believe the -Ready to Race- line, only expect one race!
Sounds like the guys at the shop had the issue not the bike.
Sounds like a good argument for why racers should also learn how to turn their own wrenches. But really, I would consider taking this shop owner to the small claims court. I would sue for any and all costs charged you due to their error. Maybe you can sue for some of your time they wasted, as well.
It would really raise my ire for him to be ignorant enough to act belligerent towards me, on top of everything they screwed up. At the very least I would cost him much further business by telling everyone about his non-professional, belligerent attitude and shoddy workmanship. He should show more pride in the work his shop puts out. I would be ashamed to be in his position.
I have a 2003 ktm 525 sx that works fine on the motocross track. Once you take it for hard enduro riding, all sort of problems start. Once it blew the water pump seals, and another time the rubber grommet that holds the stator wires popped out and I lost all oil. I can't understand why it happened, was it because it got hot and built a lot of pressure? Has anyone had a similar problem?
I just bought a brand new 06 KTM 525 SX. I have ridden it three times.
I stalled it in a mud hole full of water just under the foot pegs. When I kicked on it to restart it, it sucked water into the crankcase vent tube and filled the crankcase with muddy water. Needless to say it ruined the engine.
When I took it to KTM, they informed me that the bike had a 30 day warranty, and was no longer under warranty.
I've noticed all the 07 bikes have the vent tube routed up the air box instead of under the engine. Any one who has one of these, I recommend rerouting the the poorly located vent tube and save your bike from imminent failure.
That does seem a bad fault with the bike, however I've seen quite a few motox bikes that have this design.
Maybe you should have pulled it out first?
I've had my KTM 525 since 2005, it's a 2004 model. It's not had any problems except the stand broke off and the oil screen plug got chewed up once. Other than that, it's been fine. I've just done the servicing as and when, and it's behaved perfectly.
Sounds like you had a run of bad luck matey. These bikes are the nuts as far as I've seen.
WARNING: Do not buy a KTM if you don't know the first thing about turning a spanner!
KTM's are definitely "race" ready.
They are a race machine; you don't buy an F1 car for fetching the shopping and expect it to run for 10,000 miles without an oil change. It's the same thing!
Unless to have a deeper wallet that Richard Branson, or your name is David Knight, servicing by a dealer is not an option, so get yourself a decent socket set and expect to have to use it!
I have a 2007 525 EXC and the bike has never had a single problem. I have always turned my own wrench; it's the only way to get the job done right the first time.
My father and brother both have 525 EXC's - they are great on trails, woods and open areas. However, at 14,000 feet in Colorado I have seen numerous problems. My father had a lot of trouble with overheating as well as my brother. Leaking antifreeze out of the caps. My brother's bike broke the bolts on the top of motor and lost a lot of oil, and had them replaced with "factory upgraded ones." Well the next year my father had the same problem and had the same solution.
Again, this year my brother's bike snapped the bolts again - well it did make one trip. OK, bad luck - for them both - money is no problem - it's the riding that's impossible.
My Honda has made the trip 8 years now, no trouble. They're just high maintenance bikes; really high maintenance at almost 15,000 feet.
I own an 07 525exc. De-restrict the pipe and re-jet for overheating issues, other than that this bike runs great!
Change the oil, filters every third drain/fill and valve checks every third oil change and waallaaww! You've got a damn reliable DS!
I'm surprised at those motor failures, KTM is an outstanding company and for the most part these are very reliable motors!
I have an 06 525 EXC and can relate to the boil over issues, but only during slow technical riding when obviously there is no air flow.
Solution: get the 95.00 bolt on cooling fan (KTM accessory). Your EXC has all the connectors built in to factory wiring harness and it comes with thermostat, so the fan only comes on when needed. The only drawback is battery life suffers, but it's well worth the extended engine life and no hot anti-freeze on my riding pants! I'm approching 2500 mean AZ desert miles with an occasional 8k high riding weekend thrown in and have had 0 mechanical failure.
Change the oil every 2-400 miles and adjust the valves every 20-30 hours, and I couldn't be happier with this bike!
I got a new 2007 KTM 450 EXC Dual Sport. Bought in Jan 08 off the showroom floor.
First changed the jetting before I ever rode it. Somehow pinched that magical vent line, and vapor locked the motor, blew the head gasket, and the dealer took care of it.
I did the exhaust mod, and it really rips now.
Oil was never changed when they rebuilt my top end, and the gas tank was empty on return of the bike. Changed the oil on my own, rode the bike once, runs good, no overheating issues.
A buddy of mine rode it tonight and held it wide open at least for 15 minutes, ran the brains out of it. No problems so far I guess.
Magneto side of motor gasket torn and coming out from under the side cover. What the heck, did the dealer do in there other than ruin some gaskets? On my oil change I found pieces of gasket in the bottom of motor screen / drain plug!
I have a 2007 525 outlaw, was driving it the other day and in 5th it just quit. When I restarted it it has a rapping noise. I have checked valves and clutch everything looks good. Can someone please help?
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