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2004 KTM 525 SX

KTM 525 SX

Powerful, however controllable - not a gram too much and not a feature too little. Ready for riding 105.8 kg. The ultimate whole shot weapon. For those who really want to know what it's all about.

  • New Digi box leads to limited RPM 9800min-1.
  • New crankshaft with more inertia (removable additional weight) offers more traction and better handling.
  • New single tube exhaust pipe, reshaped main silencer, ovalised inner chamber for greater torque (smaller and lighter like the 450 SX 2003).
  • High specification chromoly frame features reduced wall thickness at the frame loops of the Racing models from 1.8 mm to 1.5 mm contribute to lower overall weight (total frame weight now less than 9 kg).
  • New forged parts work as linkage carrier (in the swing arm and foot peg area).
  • Reinforced steering head gusset plate for more reliability.
  • Swing arm pivot increased 2 mm to 17 mm diameter.
  • 10 mm longer swingarm offers more traction and more room for the rear wheel.
  • Newly adjusted WP 48 mm USD fork features three bushings - fork is more supple and offers greater sensitivity.
  • Newly tuned WP PDS rear shock absorber.
  • New, even lighter, perforated Brembo rear brake disks.
  • Lighter round holed high end brake disks front and rear.
  • New extra light 26 mm rear brake system and integrated reservoir of the footbrake cylinder.
  • Excel rims with double-thickness spokes.
  • Bridgestone M 59 and M 70 Tyres.
  • Light, single-part plastic fender with integrated side-panels sits on a new subframe that lowers the rear end by 9 mm.
  • All models seats have a new seat base for rear fender, anchored by a single bolt located underneath the seat.
  • New larger air-filter box.
  • New air filter carrier with triple mounting pins for more reliability (2-stroke).
  • 12 mm higher conified Renthal 608 handle bar.
  • Reduced master cylinder diameter (2-stroke: 9.5 mm instead of 10.5 mm; 4-stroke: 9.0 mm instead of 9.5 mm) for a lighter clutch action and more precision.
  • Standard Dual-Component-Renthal-grips in grey/orange with soft grip area and strong side.
  • New decals for the spoiler and airbox cover.
  • New frame guards.
  • Engine - single cylinder, 4-stroke
  • Displacement (cc) - 510.4
  • Bore x stroke (mm) - 95 x 72
  • Compression ratio - 11:1
  • Starter - kick-starter
  • Transmission - 4 gears
  • Carburetor - Keihin MX FCR 41
  • Control - 4 V / OHC with roller rocker lever
  • Lubrication - pressure lubrication with 2 Eaton pumps
  • Engine oil - 1,2 l Motorex Power Synt 4T 10W/50
  • Primary drive - 33 : 76
  • Cooling - liquid cooled
  • Clutch - wet multi-disc clutch, operated hydraulically
  • Ignition - Kokusan digital 4K-3A
  • Frame - chromium molybdenum
  • Subframe - aluminium
  • Handlebar - tapered Renthal 28 mm
  • Front suspension - WP-USD 48/26 MA/PA
  • Rear suspension - WP-PDS-DA shock absorber
  • Suspension travel, front/rear - 300 / 335 mm
  • Front / Rear brakes - disc brakes 260 / 220 mm
  • Front / rear rims - 1.60 x 21"; 2.15 x 19" Excel
  • Front / rear tyres - 80/100-21"; 110/90-19"
  • Transmission - 14:48
  • Chain - X-ring chain 5/8 x 1/4"
  • Main silencer - aluminum
  • Steering head angle - 63.5
  • Wheel caster - 112 mm
  • Wheelbase - 148110 mm
  • Ground clearance (unloaded) - 380 mm
  • Seat height - 925 mm
  • Fuel capacity - approx. 7 litres
  • Weight (ready to race, no fuel) - approx. 105.8 kgs