KTM 525 refresh.

[Aaron Coomer (3.504)]

mmmm

[Dark6]

Did some suspension refresh and valving changes. I'm really bad at taking pics....







Got her on her wheels, the triple tree is still being made so I just installed my 18-20mm triples until I receive the package.
Got fluids in her and kicked and kicked. No fire ugh. I did some pinpoint testing and found no spark. this is a old SX bike and about three circuits so what I was afraid of when the flywheel sheared off it hit the pickup,, I knew better than to install but I did not want to spend the money if it worked, So I ordered a new stator and pickup today hopefully I get it before I go out of town for work this week but we will see.. close to track time.

[ohioyj]

This thing is coming together quickly.

[Dark6]

She deserves it! Lookin good

she does. going to feel good getting back to the track with all her new found front end traction!

[Aaron Coomer (3.504)]

going to put that thing into the 38's!

[Dark6]

Well yesterday I was adjusting my hand guards and found a huge crack under my throttle tube.... ugh. replaced the bars with what what I had Renthal TwinWall the BEST! Well tonight while swapping the bars the guard mount wedges broke, no problem I'll just put the screw in type that we use in our enduro bikes... The issue is the twinwall have a .62 inner diameter which is 5/8 the tap and screw in type mount is a 5/8 so we would have to go to a 3/4 in the bar which would remove to much of the material. I did not want to wait to order some, so my solution was to make a mount in the lathe. I actually made two types and settled on the opposing wedge design. small job always turns to a project, hone your skills!
The new bars.



The split on the bars was big!! never seen any of these do this. I have crashed on these bars a few times and have been on the bike since 2004!!


The typical insert we use in enduro are these tap in bar mounts, these are very strong!! sadly the I.D. will not allow the use of these in twin wall bars, and there is not enough material to go to the next size.

[Dark6]

The first design mount was this sleeve type, I felt the contact patch was not enough to hold in the event of a crash.





The next design was a opposing wedge design which I cut to .0100 to the I.D. then knurled to ensure it grips in to the bar material, this design is the one I ended up using.

[ohioyj]

The issue is the twinwall have a .62 inner diameter which is 5/8 the tap and screw in type mount is a 5/8 so we would have to go to a 3/4 in the bar which would remove to much of the material.

This stuff aggravated me recently, mainly because this information doesn't seem readily available. I don't know when handle bars got so complicated (old man yells at clouds). When I replaced my handle bars the first set I ordered were "solid" all the way through. It's not like hand guards are an uncommon thing. I returned the first set (which I thought was going to be "nicer"), and ordered the same line as what I had, just a different bend.

Nice fix though!

[Dark6]

The issue is the twinwall have a .62 inner diameter which is 5/8 the tap and screw in type mount is a 5/8 so we would have to go to a 3/4 in the bar which would remove to much of the material.

This stuff aggravated me recently, mainly because this information doesn't seem readily available. I don't know when handle bars got so complicated (old man yells at clouds). When I replaced my handle bars the first set I ordered were "solid" all the way through. It's not like hand guards are an uncommon thing. I returned the first set (which I thought was going to be "nicer"), and ordered the same line as what I had, just a different bend.

Nice fix though!

Yea I was annoyed by the lack of fitment, but my ability for a solution helped me build more skilset. but I get it. Twin Wall or Nekin is the only bars I will run.