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Projects: KTM

Project Old School KTM 380: Rebuilding the Bottom End

November 4, 2009

In our last installment, the 380 motor was back from getting the crank rebuilt and the cylinder porting cleaned up. Now it's time for the bottom end.

Project Old School KTM 380: Rebuilding the Forks

September 22, 2009

Having ridden a 2002 model bike with stock 43mm forks we can say that we think something was probably done to our forks because the stock 2002 forks had a near deadly mid-stroke harshness that our forks didn't exhibit at all.

Project Old School KTM 380: Motor Clean-Up and Modifications

August 24, 2009

Our main objective was to rebuild both the top and bottom end to ensure our 380 engine has a long life. In addition we kept a keen eye out for anything else suspect that needed attention and ordered replacement parts where needed, such as the kick-start pawl spring. We also made a few performance modifications to spruce up mighty 380 a little bit yet not go over-board.

Project Old School KTM 380: Splitting the Case

March 18, 2009

When a bike is left to sit for extended periods of time the seals can dry out and become brittle and prone to leaking.

Project Old School KTM 380: Chassis Tear Down

February 23, 2009

Another area of a used bike to check thoroughly is that of the chassis and other attached parts. This includes things like suspension, swingarm and steering head bearings as well as a general inspection of the frame and swingarm for cracks or extreme wear.

Project Old School KTM 380: Top End Tear Down

January 15, 2009

To find out the current condition of the motor we decided a top-end teardown was in order. This will allow us to find out firsthand the condition of the head, cylinder and piston as well as giving us a good feel for the overall condition of the motor.

Project Old School KTM 380 MXC

December 8, 2008

While the four-stroke can put the power to the ground effectively there is nothing quite like the feel of the two-stroke snapping to attention or exploding out of a berm. A two-stroke may not find the traction like a four-stroke but it has other strengths that a four-stroke just can't match.

Project Updates and Product Review: BulletProof DesignsBilletRadiator Guards

April 1, 2006

Since our last article the 525 has provided us with many miles of fun. The orange giant has taken us on numerous desert rides, over plenty of nasty singletrack, on a few dual-sport rides and even found its way onto a few motocross tracks. The 525 handled each of these scenarios remarkably well. This fact can be partially attributed to the extremely rider friendly and torquey motor, partially to a chassis that isn't overly stiff but can take a beating and partially to the Novation suspension that has proven to be so versatile in varying conditions and terrain we expose the bike to.

Ironman Sprockets

January 1, 2005

After spending quite a bit of time over the last year riding on technical single-track trails like Kennedy Meadows and Frazier Park in Southern California I found myself wishing for a bit lower gearing on the 525. Even though it is the EXC model with the low first-gear the bike does still require quite a bit of clutching through the rock sections. In addition once you clear the technical stuff the bike doesn't seem quite happy to lug along in third, instead it requires a bit of shifting between..

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