20 Most Recent 2005 KTM EXC 525 Racing Questions & Answers

Charging system has failed. Either the voltage regulator or charging coil on the stator.

2005 KTM EXC 525... | Answered on Apr 04, 2014

I don't too much about that kind of thing personally. So whenever I have a problem I just have a auto electrician perth take a look for me. They can fix the problem way better than I could anyway.

2005 KTM EXC 525... | Answered on Jan 29, 2014

be careful, the front forks are under a spring. Just keep going and BE CAREFUL.

2005 KTM EXC 525... | Answered on Jan 10, 2013

Radiator hoses usually only need changing if they leak or are very perished. An '05 should have reasonable condition hoses. If they do need changing or you are putting some crazy colored hoses on:
1. Take off your radiator cap.2. You may need to take the fuel tank off in some cases.3. Get a 2 litre container with a large opening or funnel ready to catch your coolant.

4. Undo the coolant drain plug/bolt on the water pump and use the container to catch the flowing coolant, it may squirt a little.
5. Match your new hose to the same section on the bike and make note of the way it is installed.
6. Loosen the hose clamps on the section you are working on and push them back along the hose a little way.
7. Gently twist and pull the hose away from it's connection points, if it's till tight loosen the hose clamp more.
8. Repeat 5,6,7 for any other hoses in the cooling system.
9. Transfer the hose clamps onto your new coolant hoses.
10. Install new hoses in the same position as your original hoses.
11. Make sure the hoses are fully pushed onto the connection plumbing.
12. Tighten hose clamps with a screwdriver, firm but not super tight or the hose clamp could become damaged.
13. Re-install your coolant drain bolt ensuring the copper washer is intact if used. Don't over tighten an alloy thread if applicable.
14. Fill your cooling system with anti boil / anti corrosion coolant, gently rock the bike from side to side to allow air to escape, top up as required.
15. Install your radiator cap.
16. Start the bike and check for coolant leaks or drips.
17. Re-tighten hose clamps if required.
18. Ride the bike around for a short time and check again.
19. Check the coolant level in the radiator, top up if required.
20. Ride Hard! (Always check the coolant level at regular intervals as a lack of coolant can lead to engine failure). General advice only.

2005 KTM EXC 525... | Answered on Jan 10, 2013

Thanks for contacting FixYa. I was reviewing some of the older un-answered questions trying to make sure your issue was resolved.

Usually 2nd gear whine is caused by bent shifting forks or dogs and the gear is wearing incorectly. The best solution is pulling the engine, splitting the cases and replacing the worn, bent, or broken parts.


2005 KTM EXC 525... | Answered on Oct 28, 2011

Yes replace statter?


2005 KTM EXC 525... | Answered on Aug 20, 2011

that is caused by too much air intake

try adjusting the carborator screw

good luck!

2005 KTM EXC 525... | Answered on Mar 24, 2011

yes. like any bike your local dealer can restrict it for you.
i would question why you would want to restrict the 525 when it would be easier to get a 250 and restrict that instead. the difference would be much less noticeable and you wouldn't feel like you were riding a castrated bike. i'd wait for your licence upgrade to get a 525. or just do your accelerated access in the mean time and get the 525 in it's natural form. if you can afford a 525 you can afford accelerated access.

2005 KTM EXC 525... | Answered on Sep 07, 2010

sounds rich, especially if its a problem when it warms up, was the JD kit a much bigger main jet,might need to try standard main, is it standard exhaust, I assume the air cleaner is clean and good condition, the foam can deteriate over time.Not sure if you have a hot start button or lever, this leans the mixture, if you have one and it helps then its definately rich

as a non related hint I use moreys upper cylnder lube in my WR it starts easier, idles easier, doesnt stall as easy under hard braking, and doesnt seem to get as hot and ping when working hard in tight bush.

2005 KTM EXC 525... | Answered on Apr 28, 2010

Cold starting needs a really good spark and very little air .check your spark plugs and that your choke is working properly .

2005 KTM EXC 525... | Answered on Mar 14, 2010

First take a look at the plug color. Should be tan to a light chocolate. White is too lean. And don't overlook the valves. Adjust as needed.

2005 KTM EXC 525... | Answered on Jan 17, 2010

Hi and welcome to FixYa,

Initially, determine if there is a clicking sound when the START button is pressed. The click is significant. If there is, this indicates that the starting relay is engaging but for some reason, the starter motor is not cranking. This could either indicate a faulty starter relay (particularly the contacts) or a faulty starter motor (specifically, the carbon brushes). To determine which:
  • with the side covers off, expose the starter relay particularly the 2 large terminals;
  • have somebody start the bike normally using the key and button start switch;
  • determine if indeed the clicking is coming from the starter relay;
  • while the start button is still pressed, jump the 2 big terminals;
  • if the engine cranks, then the internal contacts of the starter relay are corroded or burned;
  • if the engine will not crank, then the starter motor is faulty.
Good luck and thank you for using FixYa.

2005 KTM EXC 525... | Answered on Feb 22, 2009

all was good!! any ideas what happened and can I fix it so it doesn't do it again?i think you'll find the crapy standard slave cylinder is about to expireget a nice billet aluminum one from evoluzione cyclesports in California at evoluzione.net. Iv'e had one on my 990SM since March and have done 5500miles with no hint of troubleit has double '0' rings on the piston,the KTM part only has one which allows the piston to cock-over and leak fluid,just take yours off and have a look. I had 2 fail on my 950SM and 1 on the 990SM,the mineral clutch fluid gets very black from engine heat,changed the fluid several times but never could trust the standard one wasn't gonna let me down.,,,

2005 KTM EXC 525... | Answered on Nov 10, 2008

which one would be the best?First of all there is no sxc it's sx exc mxc. The difference in the sx and exc is the sx is strickly a mottocross bike. It is not geared or setup suspension wise to ride in the woods. It is much more radical than an exc which is designed specifically for woods riding.,,,

2005 KTM EXC 525... | Answered on Nov 10, 2008

Kronreif and Trunkenpolz (men who found the company) Mattighofen (town where company founded). ,

2005 KTM EXC 525... | Answered on Nov 10, 2008

Not finding what you are looking for?
2005 KTM EXC 525 Racing Logo

24 questions posted

Ask a Question

Usually answered in minutes!

Popular Products

Top KTM Experts


Level 3 Expert

85239 Answers

Gino Cussen
Gino Cussen

Level 2 Expert

217 Answers

Arnie Burke
Arnie Burke

Level 3 Expert

6528 Answers

Are you a KTM Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides

View Most Popular

EXC 525 Racing KTM

  • EXC 525 Racing KTM

Most Popular Question

electric start works first try but

  • Motorcycles