520 exc or GP450

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Scrumpymonkey
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520 exc or GP450

Post by Scrumpymonkey » Mon May 25, 2020 7:28 am

Advice and thoughts from the ADV community. Got the opportunity to buy a 2002 520 exc which I'm considering using as the basis for a rally/ dual sport project. I've got the cash for the initial outlay and then I intend to do the rest of the project over the next 12 months before the rescheduled ABR rally ;) Is this a good idea or am I a complete and utter idiot?

The alternative is a 2016 CCM GP450 with the factory exhaust and power commander shenanigans fitted. I don't have the funds for this so it would be on the tick. I have done a bit of reading up on this bike and I'm worried that I would be spending the next 12 months farkling all the "weak" points that CCM didn't quite get sorted on this bike and be in debt too.

Thoughts, advice, abuse?

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Re: 520 exc or GP450

Post by PHILinFRANCE » Mon May 25, 2020 7:40 am

520...................RFS engine ...................nuf said ............................i have one ;)

Scrumpymonkey
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Re: 520 exc or GP450

Post by Scrumpymonkey » Mon May 25, 2020 8:15 am

PHILinFRANCE wrote:
Mon May 25, 2020 7:40 am
520...................RFS engine ...................nuf said ............................i have one ;)
:D

one nil to the 520

Snaf MKII
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Re: 520 exc or GP450

Post by Snaf MKII » Mon May 25, 2020 8:46 am

I'm another one for the KTM RFS but you do need to be aware that some pre 2004 KTM spares are now obsolete. Things like header pipes and exhaust manifolds are becoming hard to find in good condition as are front wheel hubs. That is an 18 year old bike

We have several KTM RFS engined bikes with very high hours on that need complete rebuilds and have decided that buying news bikes is more economical whilst keeping the older bikes going with what we have and accepting they will need constant fixing/gaffer taping/cable tying.

List of things to check on the 520.
Front forks and wheel spindle with the smaller bearings, the forks wear where the spindle goes through and you can't tighten the spindle.
Header pipes are obsolete.
Lower frame rails rusty/holed.
Wheel rims corrosion on the D.I.D. rims if they have not been replaced by later ones.
Rear mudguard/light holder now obsolete.
Sprocket Counter shaft, now obsolete.

I priced up restoring our two 2002 RFS KTM's including an engine rebuild, replace forks with later ones, new wheels, new plastics, new wiring loom etc etc and it was £4500 each. If I were to dualsport/rally build that it would be another £2k on top.

I've no idea what the CCM is like but did look at them when they came out and like the idea of them but for what we do the enduro bikes are better.

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Re: 520 exc or GP450

Post by Snaf MKII » Mon May 25, 2020 8:48 am

PHILinFRANCE wrote:
Mon May 25, 2020 7:40 am
520...................RFS engine ...................nuf said ............................i have one ;)
Only one?

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Re: 520 exc or GP450

Post by Scrumpymonkey » Mon May 25, 2020 8:51 am

Snaf MKII wrote:
Mon May 25, 2020 8:46 am
I'm another one for the KTM RFS but you do need to be aware that some pre 2004 KTM spares are now obsolete. Things like header pipes and exhaust manifolds are becoming hard to find in good condition as are front wheel hubs. That is an 18 year old bike

We have several KTM RFS engined bikes with very high hours on that need complete rebuilds and have decided that buying news bikes is more economical whilst keeping the older bikes going with what we have and accepting they will need constant fixing/gaffer taping/cable tying.

List of things to check on the 520.
Front forks and wheel spindle with the smaller bearings, the forks wear where the spindle goes through and you can't tighten the spindle.
Header pipes are obsolete.
Lower frame rails rusty/holed.
Wheel rims corrosion on the D.I.D. rims if they have not been replaced by later ones.
Rear mudguard/light holder now obsolete.
Sprocket Counter shaft, now obsolete.

I priced up restoring our two 2002 RFS KTM's including an engine rebuild, replace forks with later ones, new wheels, new plastics, new wiring loom etc etc and it was £4500 each. If I were to dualsport/rally build that it would be another £2k on top.

I've no idea what the CCM is like but did look at them when they came out and like the idea of them but for what we do the enduro bikes are better.
Thanks, that's a very comprehensive reply and given me a lot to think about.

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Re: 520 exc or GP450

Post by Snaf MKII » Mon May 25, 2020 9:01 am

Don't let that put you off, try and find the latest 525 RFS KTM that you can in the best condition. They seem to be fetching good money at the moment but once you've bought it you'll never sell it.
What sort of money is the 520?

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mark vb
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Re: 520 exc or GP450

Post by mark vb » Mon May 25, 2020 10:04 am

Snaf MkII.... interesting reading the above (albeit I'm not remotely 'into' KTM's).... do you own/run/work at an off road school/rental set-up?
OP - sorry to go off topic but I'm curious ☺

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Re: 520 exc or GP450

Post by PaulinBont » Mon May 25, 2020 11:25 am

I can't comment on the KTM but on the CCM , you really felt like it would go anywhere; I did a 10, 000 mile trip on mine and it was very easy to ride each day. I do have reservations though on how long CCM will keep supporting this bike as they have moved away from specialising in what could have been a very promising ADV bike portfolio , into the Sunday ride' custom' sector. The CCM was a very promising low-weight Adventure Bike , albeit with it's own shortcomings; which could have easily been sorted if the commitment to the sector was maintained. I'm not sure what their spare parts inventory looks like long-term?

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Re: 520 exc or GP450

Post by PHILinFRANCE » Mon May 25, 2020 11:51 am

Snaf MKII wrote:
Mon May 25, 2020 8:48 am
PHILinFRANCE wrote:
Mon May 25, 2020 7:40 am
520...................RFS engine ...................nuf said ............................i have one ;)
Only one?
:lol: One 520 but only another 2 now 400 and 450 sold 3 400s a couple of months back :(

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