The 2003-2004 KTM 525 EXC is a formidable off-road package, expertly combining a precise-shifting 6-speed transmission with a potent 510cc, 4-valve OHC motor. This liquid-cooled engine delivers a substantial 34 lb.-ft. of torque at 6000 rpm, with a linear power curve that makes it extremely versatile.
With a low first gear and an electric start, tackling even the steepest hill climbs or complicated single-tracks is a breeze. The 525 EXC’s 58.3-inch wheelbase belies its exceptional agility, feeling lighter and more nimble than its 265 lbs. full of fuel would suggest.
Low rpm power delivery is one of the bike’s standout attributes, making it feel even more potent than its dyno results reveal. Whether navigating technical trails or high-speed turns, the 525 EXC’s motor revs quick and pulls hard, yet never seems harsh.
Key Specifications
Engine Type
Four stroke, single cylinder, SOHC, 4 valves per cylinder
Engine Capacity
510.4 cc / 31.1 in
Fuel Tank Capacity
8.5 L/ 2.2 US gal / 1.9 Imp gal
Seat Height
36.4 inches / 925 mm
*n/a – information not provided by manufacturer
All Specifications
Make & Model
Model
KTM 525 EXC
Year
2003 – 2004
Engine
Engine Type
Four stroke, single cylinder, SOHC, 4 valves per cylinder
Displacement
510.4 cc / 31.1 in
Bore x Stroke
95 x 72 mm
Engine Management System
KeihinMX FCR 39
Cooling System
Liquid cooled
Performance
Top Speed
n/a
*n/a – information not provided by manufacturer
Transmission
Gearbox
5 Speed
Final Drive
Chain
Electrical & Electronics System
Starter
Electric & kick
Chassis & Suspension
Front Suspension
43mm WP USD fork
Rear Suspension
Fully adjustable WP
Wheels & Brakes
Front Tire Size
90/90 – 21
Rear Tire Size
140/80 – 18
Front Brakes
Single 260 mm disc
Rear Brakes
Single 220 mm disc
Dimension & Weights
Seat Height
36.4 inches / 925 mm
Wheelbase
58.3 inches / 1481 mm
Fuel Tank Capacity
8.5 L/ 2.2 US gal / 1.9 Imp gal
Dry Weight
112 kg / 247 lbs
Features
Four-stroke, single cylinder engine
SOHC, 4 valves per cylinder
Liquid-cooled motor
4-valve OHC motor
6-speed wide-ratio transmission
Electric start
Kick-starter
58.3-inch wheelbase
265 lbs full of fuel
Slim and lightweight design
Long-stroke Single engine
95 x 72mm bore and stroke
11:1 compression ratio
34 lb-ft of torque at 6000 rpm
44.4 hp at 7600 rpm
Linear power curve
Chrome-moly steel chassis
Double-cradle design
Removable aluminum subframe
Skid-plate recommended
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*We strive to provide the most comprehensive and accurate specifications possible. However, certain details may not be available if the manufacturer did not disclose them or if the information is no longer publicly accessible. If you find any discrepancy with any data on this site, please feel free to let us know at contact@throttlecraze.com
