KTM 525 EXC RACING 2006 User Manual (English)

Questions and Answers:

A
Aaron MontoyaAug 14, 2025
Why does my KTM Motorcycle engine get too hot?
- A
  Annette WagnerAug 14, 2025
  If your KTM Motorcycle engine is overheating, several factors could be the cause. First, check and refill the cooling liquid, also inspect the cooling system for any leaks. Ensure there's adequate airflow while riding; consider retrofitting an electric fan if needed. Make sure the cooling system is properly bled and the radiators are clean. If foam is present in the cooling system, replace the coolant with a brand-name antifreeze liquid. Inspect cooling hoses for bends and replace if necessary. Check the thermostat for proper operation (opening temperature 70°C or 158°F). If you have an XC Desert model, check and replace the fan fuse if blown.
R
Ronald BakerAug 17, 2025
Why my KTM 525 EXC RACING 2006 engine will not reach full power?
- H
  Holly YoungAug 17, 2025
  If your KTM Motorcycle isn't reaching its full power, start by checking the fuel system and carburetor for dirt or blockages, and clean them if necessary. Replace the float if it leaks. Ensure the air filter is clean; if it's very dirty, clean or replace it. Inspect the exhaust system for damage and ensure it's tight; replace the glass fiber yarn in the exhaust silencer if needed. Also, check and adjust the valve gap. Finally, check the setting of the hand decompression cable.
D
Derrick GarciaAug 25, 2025
How to fix KTM 525 EXC RACING 2006 Motorcycle when engine doesn’t crank?
- B
  brewerstephanieAug 25, 2025
  If your KTM Motorcycle engine doesn't crank with the E-starter, the issue might be a blown fuse. To resolve this, dismount the left paneling and the filter box cover and replace the fuse in the starter relay. Another possibility is a discharged battery; recharge it and investigate the causes of the discharge. Also, ensure the emergency-OFF switch is turned on (Australia only).
A
Andrew CarterAug 27, 2025
What causes a KTM Motorcycle engine to fail to idle?
- D
  dwattsAug 27, 2025
  If your KTM Motorcycle engine fails to idle, the problem could be a clogged idling jet. Disassemble the carburetor and clean the jets. Also, the spark plug may be defective and require replacement.
P
Peter BurnsAug 30, 2025
What to do if KTM Motorcycle engine stops or splutters in carburetor?
- C
  Crystal MeadowsAug 30, 2025
  If your KTM Motorcycle engine stops or sputters in the carburetor, it could be due to insufficient fuel. Clean and check the fuel system and carburetor. Also, check the rubber sleeve and carburetor for a tight fit, as the engine might be taking in air uncontrollably.
T
Thomas BrownSep 3, 2025
Why does my KTM 525 EXC RACING 2006 have high oil consumption?
- M
  morganclineSep 3, 2025
  If your KTM Motorcycle has high oil consumption, check if the hose of the engine ventilation is bent. If it is, dislocate or replace it with a non-buckling ventilation hose. Also, check the engine oil level and correct it if it's too high. If the motor oil is too thin, use a thicker engine oil.
R
Rhonda BennettSep 6, 2025
What to do if horn, flasher lights and E-starter do not work on KTM Motorcycle?
- E
  Elijah CruzSep 6, 2025
  If the horn, flasher lights, and E-starter on your KTM Motorcycle aren't working, it may be due to a blown fuse in the starter relay. To fix this, dismount the left side paneling and filter box cover, then replace the fuse.
C
Chelsea PruittSep 9, 2025
Why KTM Motorcycle engine does not rev high?
- M
  Maria MclaughlinSep 9, 2025
  If your KTM Motorcycle engine does not rev high, the carburetor fuel level might be too high because the float needle valve is dirty or worn out. Dismount the carburetor and check if it's worn out. Also, tighten the jets.

KTM 525 EXC RACING 2006 Specifications

General

Engine Type	Single cylinder, 4-stroke
Displacement	510.4 cc
Bore x Stroke	95 x 72 mm
Compression Ratio	11.5:1
Transmission	6-speed
Fuel System	Keihin FCR 41
Ignition	Kokusan digital
Seat Height	925 mm
Dry Weight	107 kg
Cooling	Liquid-cooled
Front Suspension	WP 48 mm USD
Rear Suspension	WP PDS shock absorber
Front Brake	260 mm disc
Rear Brake	220 mm disc
Starter	Electric