KTM 525 EXC Racing - 2004 Specifications and Reviews

The 2004 KTM 525 EXC Racing is a high-performance enduro machine built for serious off-road competitors and experienced riders seeking maximum power and reliability. Its potent 510cc liquid-cooled four-stroke engine delivers strong torque across the rpm range, while the WP-USD 48 suspension and rigid chromoly frame provide excellent handling on demanding terrain. Known for its legendary durability and race-proven engineering, the 525 EXC dominated enduro competitions throughout the mid-2000s.

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General information

CategoryEnduro / offroad
Year2004
ModelKTM 525 EXC Racing

Engine and Transmission Specifications

Transmission type,final driveChain
Gearbox6-speed
Cooling systemLiquid
Fuel controlOHC
Fuel systemCarburettor
Bore x stroke95.0 x 72.0 mm (3.7 x 2.8 inches)
Compression11.0:1
Engine typeSingle cylinder, four-stroke
Capacity:510.40 ccm (31.14 cubic inches)
 
 

Brakes, suspension, Frame and wheels

Rear brakes diameter260 mm (10.2 inches)
Rear brakesSingle disc
Front brakes diameter216 mm (8.5 inches)
Front brakesSingle disc
Rear suspensionWP-PDS-shock absorber
Front suspensionWP-USD 48 MA
Rake (fork angle)5.0°
Frame typeChromium molybdenum
 
 

Physical measures and capacities

Fuel capacity8.50 litres (2.25 gallons)
Wheelbase1,481 mm (58.3 inches)
Ground clearance385 mm (15.2 inches)
Overall width525 mm (20.7 inches)
Overall height525 mm (20.7 inches)
Alternate seat height675 mm (26.6 inches) If adjustable, highest setting.
Seat height925 mm (36.4 inches) If adjustable, lowest setting.
Dry weight117.2 kg (258.4 pounds)

Other specs

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Performance Profile & Rider Fit

Best For

Track30%
City20%
Cornering70%
Daily Riding15%
Touring20%
Passenger5%

Rider Profile

Best ForThis is a serious competition enduro machine best suited to experienced off-road riders comfortable with a tall, light, high-strung race bike.
PurposeBuilt purely for enduro racing and technical off-road riding, not as a road or all-round machine.
Rider FitThe tall 925mm seat height, minimal seat padding, and kick-start-only setup demand good fitness, leg length, and off-road riding skill.
CharacterA featherweight, high-revving single-cylinder racer with razor-sharp handling, huge suspension travel, and a raw, focused competition feel.
Not Ideal ForThis bike is not suitable for riders wanting a comfortable commuter, a passenger-friendly tourer, or a beginner-friendly first motorcycle.

Character map is an editorial estimate based on this bike's specifications, not a lab-tested measurement.

Rider Fit Visualizer

2004 KTM 525 EXC Racing Rider Ergonomics Assessment

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Feet:

At 925mm, a rider of 175cm with a 79cm (estimated) inseam will reach the ground with cannot reach comfortably on the 2004 KTM 525 EXC Racing, with a cramped knee angle of around 80 degrees and an upright riding position.

Data quality: measured. Assumes about 30mm of suspension sag once seated (a typical street-bike rule of thumb - stiffer or softer suspension will vary). This is an approximation from category-typical geometry and generic body proportions, not a measurement of this specific bike or you - sit on it before you buy.

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