20 Most Recent 2005 KTM 525 EXC Racing - Page 3 Questions & Answers

Lots of engines make characteristic noises and air-cooled 2-strokes have lots of characteristic noises even when new and even when there is nothing wrong. If you have just spent a parcel of money on it your first port of call should be to the person or dealer who carried out the work. Having a top and bottom overhaul means a world of different things to different people. If you don't know what has been done and what needed to be done you will be somewhat in the dark and at a disadvantage with perhaps unrealistic expectations. Perhaps the engine hasn't had as much of an overhaul as you thought. A full bottom end overhaul is a good deal of cash and lots of work that would make it as good as a new engine again. Maybe the dealer decided for reasons of economy to refit some of the old parts instead of replacing everything. I suggest you read your invoice and then go and ask some leading questions.

no any single blinker will work , probably at a faster rate if the other same side blinker is not operational check the wiring back to the switch and check the blinker can

Too many possibilities for this site. Get hold of a local biker/shop to help.

if it is running and not making any noises then I would only consider the piston, rings and liner as a last resort If it has valves , (4 stroke) , check the valve clearance and adjust to specifications as valve stems get longer when hot and if the clearance is not sufficient when cold then a valve will be held slightly open when hot next check the coil and ignition module and the timing

check for a bare wire touching metal .

and neither you should have to as it is a 2015 make , why have you not taken it back for a warranty fix next you would be using a single point plug ( car plug) when it would be better to use a mulit point plug ( anti fouling plug) that is available from good spares shops , motor bike shops and marine shops You mention that it fouls after sitting over night can you comment of the fouling condition( wet , black, oil ,carbon build up etc ) as the information all points to a problem area.

You need 3 thing to make an engine run.spark at the right time ,fuel /air ratio to be correct,and compression.Isuspect you have tight intake valves.The valves are to tight letting compression out.To adj valves take your plug out put motor on tdc compression stroke .intake should be .006 exhaust .008.If this checks out to be ok you may have a fly wheel key that sheared and your ignition timing is off.