I picked up a 2012 KTM 500exc last spring. I wanted something I could ride from my driveway to a large trail network that can be accessed about 6 miles from my house.
It had 25 hours on it and 1100km on the odometer. I put 60 hours/1000 km on it over the summer, mostly tight woods single track.
A few pics in its natural habitat.
I'm not easy on this machine at all, it gets dirt naps pretty much every ride and has slid down some hills, bounced off of trees, etc. I do however try to maintain it really well. Mostly because I often ride alone 30-40km into the woods with no access other than dirt bikes, sometimes not sure I will get myself out with a running bike. Also I enjoy wrenching on bikes.
My winter project is to tear this bike down to the frame and go through all the components, addressing any issues that come up. I also have some mods/upgrades planned as well. The biggest concern I have is the wiring, KTM dirt bikes are known for bad wiring, I've already had to fix a couple broken wires. Most of the connectors are no sealed and are packed full of dirt and starting to rot and corrode. The wiring harness will get a complete inspection/repairs and all connectors replaced with sealed connectors.
Its a big list but here is what I'm thinking:
I've already started the process. Pics won't be the best for the first few posts as I wasn't planning to post any of this but should get better as we go.
It had 25 hours on it and 1100km on the odometer. I put 60 hours/1000 km on it over the summer, mostly tight woods single track.
A few pics in its natural habitat.
I'm not easy on this machine at all, it gets dirt naps pretty much every ride and has slid down some hills, bounced off of trees, etc. I do however try to maintain it really well. Mostly because I often ride alone 30-40km into the woods with no access other than dirt bikes, sometimes not sure I will get myself out with a running bike. Also I enjoy wrenching on bikes.
My winter project is to tear this bike down to the frame and go through all the components, addressing any issues that come up. I also have some mods/upgrades planned as well. The biggest concern I have is the wiring, KTM dirt bikes are known for bad wiring, I've already had to fix a couple broken wires. Most of the connectors are no sealed and are packed full of dirt and starting to rot and corrode. The wiring harness will get a complete inspection/repairs and all connectors replaced with sealed connectors.
Its a big list but here is what I'm thinking:
- Rad hoses
- Inspect clutch
- Larger idle screw
- Clean injector
- Check all wiring
- Replace connectors with Waterproof connectors (Sumitomo ?)
- Valve clearance
- inspect brakes
- Rear brake switch connector redo
- Low fuel light check
- High beam light check
- New battery
- Fork rebuild
- New Fuel pump
- Wheel bearings
- Ground strap
- Kill/start switch
- Inspect kick stand innards
- Rear sub frame corrosion.
- Fix radiator and bend tab for plastic mounting
- Install rad braces
- Replace counter shaft seal
- Fix wiring behind headlight mask
- frame guards
- New Battery in gauge cluster
- Balance wheels and check run out
- Rad cap
- Battery fitment
- Spring washer on ground cables
- Inspect water pump
- Throttle cable boot
- Elastic mount rad shrouds
- New brake pedal w/ tether
- Repack muffler
- Install threaded bar inserts
- Weld wing nuts onto throttle body bolts for trail side removal or replace with 6 or 8mm head bolt and carry ratchet wrench?
- Check condition of throttle body boot
- Fix tear in seat
- New chain sliders
- Make Rear running light stays on when headlight switch off
- Check for vacuum leaks
- Check TPS voltage
- Make short bolts for bottom or front fender
- 3m headlight lens
- Longer shift lever
- Rebuild kick stand
- Clutch Slave gasket
- Check steering head bearings
- Machine Clake 2 clamp for better clearance
- Install heavy belleville clutch spring
I've already started the process. Pics won't be the best for the first few posts as I wasn't planning to post any of this but should get better as we go.