The chassis of the 450 and 525 are identical,
and share the same chromoly steel frame, a-arms
and swingarm. Many manufacturers have been utilizing
new materials and construction techniques for
there latest racing ATV’s, but KTM decided
to go with a proven design that has been the
choice of nearly every aftermarket racing frame
builder. KTM did put their experience in building
cutting-edge MX bike frames to use, utilizing
a unique tubing shape and very well thought
out castings to elevate the level of frame design
past that of the great aftermarket frame era
of the early 2000’s. The steel frame allows
for maximum open area for machine service, and
according to Tim Farr, has had absolutely no
failures during testing. The extruded aluminum
subframe is strong and lightweight, and incorporates
a removable grab bar.
The chromoly a-arms look just like a top-of-the-line
aftermarket item, with adjustable camber, caster,
and easily serviceable ball-joints and heim joints.
The arms are the perfect width for XC racing,
and the KTM Hard Parts catalog offers a set with
increased width for MX use. The lower arms are
shaped for added ground clearance, and all bearings
are sealed for long life. The Ohlins front shocks
are fully adjustable and offer over 10”
of travel, with piggyback reservoirs and dual
rate springs. The available adjustments include
preload, compression, rebound, and spring crossover.
The rear suspension is textbook race ready,
with a chromoly swingarm and axle, eccentric
chain adjustment, and tapered roller bearings
in the carrier. The aluminum rear hubs have
a spacer that can be moved from inside to outside,
changing the width of the machine from 45.5
inches to 48.5 inches for different track conditions.
The hub nuts are self-locking, and do not use
cotter pins. The rear shock is an Ohlins PDS,
which uses no linkage and a single spring. The
internal two-piston damping system creates all
the necessary progression. KTM has been using
the “no-link” design on their dirt
bikes for years with great success, and the
extra ground clearance and simplified maintenance
is a big benefit for the serious trail rider
and off-road racer. The shock has preload, compression,
and rebound adjustments, and provides nearly
10.5” of travel. The no-link configuration
is nothing new in the ATV world, as many aftermarket
frame companies used the design for their high-end
chassis.
Taking care of the stopping duties on the KTM’s
are a powerful set of Magura brake systems. The
front is a groundbreaking 4-piston design that
has only previously been used on road bike front
calipers. The fixed calipers have two pistons
pushing on either side of the 180mm floating discs.
The non-floating caliper design eliminates several
slide pins and rubber boots, while the 4-piston
design creates unparalleled braking power. The
rear caliper is a proven single piston design,
and the 200mm rear rotor is partially vented for
proper cooling. Both front and rear brake systems
utilize stainless steel braided brake lines, and
the front rotors are wave-shaped for better cleaning
and cooling properties. The rear reservoir is
integrated with the master cylinder, eliminating
the plastic fluid container and tubing altogether.
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Magura
Hydraulic Clutch System & Reverse
Lever |
Magura
Front Brake System
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The steering in handled by a set of Magura
tapered aluminum handlebars mounted on an adjustable
aluminum steering stem. The stem provides a
total of four different front-to-rear handlebar
positions to fine tune the ergonomics to each
rider’s needs. The bar mounts are rubber-mounted
for vibration absorption, and for height changes
higher bar mounts are available through the
KTM Hard Parts catalog. The bottom of the steering
stem has provisions for mounting an optional
Ohlins steering damper, and the frame is fitted
with the proper brackets to make the installation
painless.
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Plenty
of protection is provided underneath with
a large belly pan skid plate and swingarm
skid plate along with large foot guards
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The fenders and tank are aimed at versatility,
with futuristic styling setting the look of
the machine apart from anything else on the
market. The aggressive front fenders have removable
extensions that are bolted on and can be reattached
easily. The seat is wide and soft, perfect for
long races or trail rides. A quickly detachable
hood piece can be removed easily for servicing
the machine. The fuel tank is a 3.5 gallon unit
that should eliminate most racers’ need
for refueling during an event. If refueling
is necessary, a quarter-turn cap cuts time in
the pits down considerably. The kill switch
is a major convenience for racers, who will
not have to buy a switch and splice it into
their wiring harness.
