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Project 525EXC
  • Project Updates and Product Review: BulletProof DesignsBilletRadiator Guards



    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.

    Project 525EXC - Novation Update Adjustable Progressive Dampening System



    We last reported that Pete Russell from Novation had a new 3 way adjustable system for the PDS shock he calls the APDS (Adjustable Progressive Dampening System). Upon hearing about the available update we couldn't resist and sent our shock was off to Novation for a rework. For the last few months we have been testing with the updated shock and finding settings for the desert, rocky singletrack and even on a few motocross tracks. It is amazing at just how adjustable the suspension system is with the S.S. valves in the forks and the new in the shock.

    StompGrip Traction Pads Revisited



    Have a nasty habit of shredding your airbox stickers with your boots like I do? Enter StompGrip traction pads, designed to provide you with traction knobbies that help hold you in place when gripping the bike with your boots and knees. The StompGrip traction pads are designed for individual bikes out of a pliable elastomer material with the knobbies molded right in. Since the traction pads are clear you can apply them right onto the airbox over sponsor logos or stickers.

    Spare Tube Bag



    While making plans for our upcoming dualsport rides I started thinking about things that I should be sure to bring along. One of the first things that popped into my mind was to bring along besides the general tools was a spare tube in case of a flat. To secure a tube and the tools required to make the change we needed a spare tube carrier. Since our rear fender bag has proven functional and extremely durable we decided upon Dirt-Bike-Gear.coms new front fender bag.

    Oil Change - Tips and Tricks



    Over the past number of months we have performed numerous oil changes on the 525 and come up with a routine and a few tricks to make things easier. Our normal schedule has been to change the oil and clean the two screens and then on every third oil change install two new oil filters. If you're racing or really abusing your machine you may want to change the filters more often.

    Fastway FIT Handguard System - Damper Mount



    There are many options when it comes time for shopping for handguards. Our local shop had initially supplied us with Enduro Engineering handguards when buying the 525 Project bike.

    Fastway FIT Evolution II Footpeg System - F3 Series



    What do you do when you're too short for tall seat foam but you're still looking for a little more legroom on your dirtbike? Enter Fastway's F3 footpegs with their new optional "lowboy" position. During a recent ride I had the opportunity to ride a friends 525 that had tall seat foam installed. I was surprised at how much easier it was to move around on the bike, especially going from sitting to standing. Another big advantage was how much easier it was for me to get my foot set and apply pressure to the..

    DirtTricks Adjustable Offset Triple Clamps



    The 2004 KTM 525EXC comes with the 18mm offset triple clamps straight from the factory. KTM must be on to something because the '04 525EXC we rode turned better than the 2002 520 or our 2003 525. Lucky for us - Greg Burns of DirtTricks supplied us with a set of adjustable offset triple clamps to make our bike turn like it should. The clamps run $339 with the 14mm/20mm insert; for $69 more you can also get the extra 16mm/18mm insert to give you the full range of adjustability - 14mm through 20mm.

    FMF Q and Powerbomb Header System



    The decision to purchase an aftermarket exhaust for a four-stroke dirt bike is getting tougher each year. Current sound restriction laws combined with the already high tech factory exhaust designs don't leave a lot of options for those of looking for more performance without the price of a thundering exhaust note. Dirt bikers who are riding in public areas and off a closed course should want to keep their exhausts as quiet as possible out of courtesy and the desire to protect our right to ride responsibly...

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