20 Most Recent 2007 KTM 525 EXC Racing - Page 4 Questions & Answers

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.

Its not to bad .You will need to purchase a shift shaft a shift shaft seal and a primary cover gasket and oil.First drain your oil.Remove your kick starter .Remove your primary cover.Remove entire clutch assembly.You will need air gun or a clutch holding tool to remove the clutch.Once you have the clutch assembly removed yuo can remove the shift shaft .Pay attention to the postion of the shift shaft in relation to the shift drum .Also pay attention to any shims on the shift shaft as that will need to be installed on the new one.Now remove the seal that the shaft was coming out of.Replace the seal install the new shift shaft.Make sure to center it in relation to the shift drum.clean every thing with brake cleaner.clean gasket area .Install the clutch assembly .If you have any trouble with the oriantation of the parts you can look at world of power sports for parts diagrams.Make sure you tighten the clutch hub to the proper torque spec.I would use blue loc tight on the nut as well .If you have a shop do it expect to pay about 2 hours labor max.Plus parts

Brand new ngk plugs are pre gapped but in thousanths .28 to .32 works

These bikes ran hot from brand new.Im guessing that the radiators are in good shape and the water pump is also?If so try running evans coolant.If your riding in a lot of slow speed enduro single track you may want to consider an electric fan available from your local ktm dealer.

Hi im guessing your year to be 1981 or 1982.First if you have not done so make sure your coil is grounded.Next disconnect your kill switch.Next check the primary side of the coil .3 to .5 ohms check the secondary side of the coil 5k to 7k ohms with out the spark plug cap.While your at it check for spark with out the cap.Make sure your kicking it fast as motoplats do not spark below 700 rpm.If all else fails you have a few choices .Vance smith can rebuild yours for under 200.00 usally.You can go with a pvl ignition for around 500.00.Also make sure your crank bearings are tight and your mag side crank seal is not leaking if you smell fuel in the mag cover you need to replace your crank seal good luck

run a compression check to see if it is low. If low squirt some oil in cylinder and rerun. If it stays low possible valve guide problem. If oil fixes compression then the rings are bad.

A backfire is unburnt fuel igniting. Check you have no air being drawn into the engine through a split in the carb rubbers or a loose carb rubber clamp. The easiest way is to let it idle/tick over and spray some carb cleaner around the rubbers. If the engine stutters or stalls then this is where the leak is. An unsealed collector box will cause this to happen as well so check that your exhaust system is correctly sealed and fitted.

replace the throttle spring and take the handle off and grease in there

Hi,again so its not hidrolic clutch its a cable so this should be easyer to sort out just follow the advice I gave in your first question. good luck

Is it a rotax engine ?

http://www.pdfmotomanual.com/index.php?r=site/page&view=manuales&order=t&key=K&make=2016&lang=ENG Loads on the above link for a 450 EXC

First check the gas. Then go for the electrical system.

There is no fixing a head gasket. Replace it.

first replace the fuel filter.

That is an annoying problem, huh? Have you properly adjusted the clutch freeplay both at the handlebars and at the clutch arm? If you are still having trouble getting the clutch to let go, you might consider checking to see if the clutch springs are shot, but I doubt this on such a new bike. In fact I'm curious if you have a cable clutch at all, or if you have a special hydraulic setup. Anyway, once you get the clutch operating you can get out of 5th gear by pulling the clutch and rocking the bike back and forth while shifting down. Do this with the engine off.

thats easy take clutch cover off and watch how the plates are on and just copy it excactly the same

sound to me like the clutch slave cylinder. follow the pipework down from the bars to the casing. Unbolt the slave cylinder and im guessing it will be covered in break fluid. new slave cylinder is the answer hope this helps

You might find the manual and wiring here.. http://www.manualedereparatie.info/en/categorii/ktm.html please rate me if this helps. Thanks

Check for a good strong spark at the plug itself. If its not there you have a bad coil, loose, broken, corroded wires or bad grounds.