Question about 2005 KTM MXC 525 Racing

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Starter gear I just purchased a new 525 MXC in January and have several good rides on it. I love the bike

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But the last ride the starter was making noises. Took it back to the dealer and he said the starter gear was broken. I had purchased it exactly 30 days prior and it has a 30 warranty so no cost to me however it this a problem anyone has had and should I be worried?,Yep, My 05 exc525 had the same problem after about 200miles, one of the starter gear teeth broke off , luckily it was caught by the sump plug and ktm replaced the gear for me. Reasons could be slightly higher compression or smaller battery doesnt have the same power but i suspect its down to a batch of the gear cogs not being properly heat treated. As long as the broken teeth went straight to your magnetic oildrain bolt i dont think you need to worry. A couple of my mates also had replacement clutches after about 100 miles on the 525s, my decals are lifting and the rear tail light connector is a bit iffy, also the single red button for the starter and no kill switch with it is naff. Having aired those few glitches, its actually the best bike ive ridden to date with the upgraded chassis and suspension, and the fork seals are spot on. I just hope that ktm dont lose the attention to detail that we all like now they are in demand.,,,

Posted on Nov 10, 2008

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