XC light flywheel update
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Thread: XC light flywheel update

  1. #41
    Junior Member Rookie
    Join Date
    Apr 2012
    Posts
    16
    I did this mod last year and had 0 issues. My bike accelerates much quicker. I am actually ruuning
    a 525sx cdi,stator,flywheel. I took off a bunch of weight and went kickstart. No lights, relay, battery,
    less wiring. You can really notice the difference in acceleration.

  2. #42
    Administrator KTMATVHQ Guru
    Join Date
    Feb 2008
    Location
    Auckland, New Zealand
    Posts
    4,264
    so you went for the old style stator / RFS cdi. What about running the cooling fan ? straight off the stator lighting circuit I'm guessing ?
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  3. #43
    Junior Member Rookie
    Join Date
    Apr 2012
    Posts
    16
    No need for a fan or lights its a hillshooter for sand. I run a mino water pump,temp gauge, and the
    t-stat delete kit from texeira. This thing only heats up to 200 if i let it idle while already hot. It will take
    About 5-10 minutes to actually get to 200 while idling. As soon as i start riding it drops back down to
    140. I have gone up and down the hill over and over again for over 1 hour in hot weather and temps
    Stay below 160. And let me tell you the older cdi really wakes up the bike. I run a ported 42mm carb
    with the tps on the fcr disconnected and it runs great. I'm stock bore with a high comp piston, 833 cam,
    Bored fcr, fmf ti exhaust, and ktm 525xc intake. Ive been like with this setup for 1 year and so far it has
    been very reliable.

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  5. #44
    Administrator KTMATVHQ Guru
    Join Date
    Feb 2008
    Location
    Auckland, New Zealand
    Posts
    4,264
    interesting, so the SX CDI, basically the map is set aggressive / allot of advance from the get go with no TPS to dial it on. Good info to know.
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  6. #45
    Senior Member KTMATVHQ Guru
    Join Date
    Jun 2010
    Posts
    1,020
    so this mod seems to be working well with no issues so far? i am currently in rebuild right now, got all the parts machined ready to put in. just wondering if anybody had any issues so far i cant see how this could really cause any problems anyway, if anything it should be more reliable.
    2009 KTM 525XC #841

    Brad Mulvey Mod SX arms, SX axle, SX brake lines, KTM Big Nerfs, KTM Hood, Motoworks SR4 slip on, akro manifold, ESR heat gauge, 42mm bored carb, hrc kit, YFZ float bowl w/ adjustable leak jet, FCI "like" Intake w/ RC-5000 K&N filter.

  7. #46
    Administrator KTMATVHQ Guru
    Join Date
    Feb 2008
    Location
    Auckland, New Zealand
    Posts
    4,264
    takes allot of end load off the crank, if anything it should help the crank and main bearing life, and add a smile to ya dial with the faster acceleration !
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  8. #47
    Senior Member Member
    Join Date
    Nov 2010
    Location
    New Zealand
    Posts
    118
    Will be test running my 450xc with this mod tomorrow, then time for the cam
    My Bikes:The Beast: Raptor660727cc (105mm piston 14.5:1 CR)3 plug HV ported headDual Kehin FCR39 carbsCustom made full dual exhaustThe Beauty: KTM450XC554 (99mm bore) with Cut7 cam & 43mm carbSX A-Arms & Yamaha Front rimsDual rate rear springs (Thanks Kiwicraig)Rear Spacers to adapt to Yamaha stud patternMods to come:Suspension nextThe SledgehammerSuzuki TL1000SOhlins rear/Racetech kitted forks

  9. #48
    Senior Member KTMATVHQ Member
    Join Date
    May 2013
    Posts
    284
    going to dig this up for a minute. i saw a ton of different flywheels listed as possible options and then a few options on case covers etc. Is there a specific setup that was found to work best and provide the cleanest installation? possibly even a parts list with part #'s?
    thinking since its only march and my race bike is about done maybe i will throw in a lighter flywheel for XC for good measure!
    Racing KTM 525xc's in WNYOA & GNCC

    Thank you 2015 sponsors!
    Rocket Ron Racing
    Immortal ATV
    KTM Parts House.com
    Motosport
    GBC
    Houser
    Spider Graphixs
    100% Goggles
    Shock Pros

  10. #49
    Administrator KTMATVHQ Guru
    Join Date
    Feb 2008
    Location
    Auckland, New Zealand
    Posts
    4,264
    RFS SX flywheel 2000-2004 59039005000 needs to be checked But I think this is the right one.................
    KTM SX Stator cover Part No 59030002500

    get the matching gasket 59030040000

    you need these two of the little spacers to get the trigger coil in the rightplace 59039009000

    TT regulator unit is part no 7004-RR150 $60 http://www.trailtech.net/7004-RR150.html

    TT stator is S-8360-05 $145 http://www.trailtech.net/S-8360-05.html

    You will need to machine inserts ti step the ATV 8mmthread down location dowels (2) and flush (2) with 5mm threads to hold the sidecase on, see the first page of this thread.
    polarisrider150 likes this.
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  11. #50
    Senior Member KTMATVHQ Member
    Join Date
    May 2013
    Posts
    284
    thanks kiwi.

    Looking up part # for 04 525sx flywheel is part # 59039105200 FLYWHEEL 4K3B RACING 2004

    (slightly different than the number you posted which crosses to: FLYWHEEL 4K3A ""K9158"" RAC.2000 (59039005000)

    Any idea what the difference between them is?

    Rest of the parts seem like they'd be easy enough.

    Lexington, Kentucky, KTM, ATV, OEM, Offroad, Street, fiche, parts, accessories, apparel, clothing, jacket, helmet, boot, glove
    Racing KTM 525xc's in WNYOA & GNCC

    Thank you 2015 sponsors!
    Rocket Ron Racing
    Immortal ATV
    KTM Parts House.com
    Motosport
    GBC
    Houser
    Spider Graphixs
    100% Goggles
    Shock Pros

  12. #51
    Senior Member KTMATVHQ Guru
    Join Date
    Jun 2010
    Posts
    1,020
    So i have been running this setup for a few years now and the response is awsome, just having some starting issues since ive done this mod. It charges at 14v when running but yet when i stop after riding it doesnt want to start. If i boost it it will start.... from what i can tell these bikes need a high voltage to actually start. Is there a way to bypass that part?
    2009 KTM 525XC #841

    Brad Mulvey Mod SX arms, SX axle, SX brake lines, KTM Big Nerfs, KTM Hood, Motoworks SR4 slip on, akro manifold, ESR heat gauge, 42mm bored carb, hrc kit, YFZ float bowl w/ adjustable leak jet, FCI "like" Intake w/ RC-5000 K&N filter.


 
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