Street legal EXC 520

[Person8]

THE LIST

Ok, here is what I was able to decipher from my notes from when I ordered the Dual Sport parts for my E/XC. This is *all* of the parts that the Euro bikes have that the US bikes don't. There may be some you don't really need. I put them all on mine, and it turned out real nice. Use your own judgement. I ordered all the parts from Stephan's Garage in Germany. Very nice guy, speaks good english, and takes credit cards for payment. Only took 2 weeks to arrive here in Texas once he shipped it. Very hassle free. I believe he has put together a package containing all these parts, so it may be best to just e-mail him and tell him what you want to do. You can contact him at :
Stephans-Garage@t-online.de

QTY _ PART NO. _ DESC

2 _ 584.14.025.000/30 _ Flasher, Complete, Left Front, Right Rear
2 _ 584.14.026.000/30 _ Flasher, Complete, Right Front, Left Rear
1 _ 490.11.435.000 _ Bulb, 12V 5W
1 _ 503.11.076.000 _ Wiring Harness, Rear
1 _ 571.11.038.000 _ Bulb, H4 12V 60/55W
1 _ 503.14.065.244 _ Speedometer
1 _ 503.14.061.100 _ Speedometer Bracket
1 _ 583.14.069.151 _ Speedometer Cable
1 _ 550.11.022.100 _ Clamp
3 _ 491.11.425.000 _ Bulb, 12V 1.2W
1 _ 503.14.069.050 _ Magnet for Speedo
1 _ 0471 009104 _ Circlip for Magnet
1 _ 580.11.021.300 _ High Beam Indicator Blue
1 _ 580.11.024.300 _ Flasher Indicator Green
1 _ 590.11.075.400 _ Wiring Harness Front
1 _ 503.11.076.000 _ Wiring Harness Rear
1 _ 590.11.083.000 _ Support Bracket
1 _ 446.11.207.200 _ Flasher Unit
1 _ 503.11.070.000 _ Light Switch
1 _ 503.11.050.000 _ Brake Light Switch Front
1 _ 545.11.060.100 _ Horn
1 _ 0014 060103 _ Collar Screw M6X10
1 _ 590.11.061.000 _ Horn Bracket
1 _ 0014 060153 _ Collar Screw M6X15
1 _ 503.11.029.000 _ Flasher Switch
1 _ 130.11.070.060 _ Adapter for Flasher Switch
2 _ 0985 040163 _ Flat Head Screw M4X16
2 _ 0084 040223 _ Cyl. Head Screw M4X22
2 _ 0934 040003 _ Hex Nut M4
1 _ 503.11.051.100 _ Brake Light Switch Rear
1 _ 590.11.080.000 _ Flash Wiring Harness Front
1 _ 590.11.081.000 _ Flash Wiring Harness Rear


Well I think that's it. All this stuff is listed in the Spare Parts Manual. No guarantees from me, but I believe these are all the things that I used to convert my bike. The best piece of advice I can give though is to contact Stephan and he'll help you sort it all out. I also bought some other cool stuff from him while I was at it. Have a look at his website at http://www.stephans-garage.de/onlineshop/start.htm . Click on the British flag for the english version.Good luck!

Larry

 

[rob_the_nailer]

Do these parts come with good installation instructions? I am especially interested in the wiring harness and if it plugs into the existing...thanks.

 

[Person8]

Actually, there were no installation instructions. I just figured it out as I went along. Wasn't difficult though. The wiring harnesses are different, and replace the existing harnesses: i.e. you can't plug the rear turn indicator harness into the existing main wiring harness. You have to replace the main harness then the front and rear harnesses will plug right in.

Larry

 

[Cappy]

Legal with KTM parts

To use all original KTM parts it is a bolt on process and has been done by several members of this and other KTM forums, with very nice results. Here is the cost in Deutsche Marks for STEGA Racing (formerly Stephan's Garage KTM) to get you all the parts you need. The current exhchange rate is somewhere around 2.13DM=$1.00US. Parts listed arecfor the 200-2001 racing 400/520 but they are pretty accurate for the 2002 model as well:
Flasher 4x 19,20
Headlight DOT 121,37
Rear-Light 62,59
Back-fender 57,81
Flasher-cable front 39,90
" " back 58,13
Flasher-relais 52,68
" switch 47,44
Head-light switch 68,58
Adapter for Flasher-switch 5,05
Brake-light switch,front 20,79
" " " back 57,35
One part is diff., the wiring-Harness Mod. 2000 62,30 " 2001 126,04
So, there is a package-price for Mod.2000 730,80 DM " 2001 794,54 DM
The prices are without german-Tax, plus shipping which I think with German-Airfraight(Post) it costs I think 110.-DM.

 

[Cappy]

STEGA Racing Info

Sorry, I forgot the contact information for STEGA Racing:
Owner: Stephan Pazdzior
Ludwig-Langestrasse 7
67547 Worms
Germany
Commercial from US: 011 49 6241 44758
Hours: Mo-Fr 1000-1900 hrs Sat 900-1400hrs Closed Sun

website: http://www.stega-racing.de

 

[Person8]

Cappy - Hey, hows it going? I thought Stephan had a package put together. That would be the way to go. I just looked at his website after not seeing it for a while - looks good! Especially the addtition of an English version. Makes it much easier for us folks over on this side of the pond.

Larry

 

[brillmtb]

To Cappy and Person8

Thanks for the info. This is going to be real helpful. I have the manual but nothing substitutes for the experience of people that have done the job.

It looked like you did need the new harness with the switches...thanks.

I also got a quote from a shop in England. Will have to see if there is really any price differences. If the guy in Germany has gone to the point of "specializing" in a package for us then that might be the best way to go. Will contact them and post results here.

 

[Tiger]

Dual-Sport Conversions

Hey guys,

I re-wound my stator, did the Baja Designs kit this past summer and was VERY disappointed with the quality of the kit. It is pricey and you do not even get all the required parts. No Odo, mirrors, fan, etc... KTM does have a "Hard Parts" catalog in their USA dealers (I have one in my hands). At the Dual Sport ride, I saw and spoke with several KTM 4-Stroke riders...fitted with European Parts (ala Stephans Garage) and can only tell you how steaming mad I was. MUCH BETTER! It's worth it. Don't even bother with anyone else...the KTM OEM parts are very slick! You can visit KTM in Australia for an actual 2002 bike outfitted with these parts. I'm droolin'.

 

[Tiger]

Websites...

What I meant to say was...visit KTM other websites (Europe, etc...) and you'll see the exact bikes (EXC, MXC) outfitted in the Dual Sport way. This makes you feel more comfortable going the dual sport route! Here's a 2002 520 EXC from Australia. FYI.

Hmmmm...it won't let me load it here. Just message me and I'll give you a copy of the photo!

 

[brillmtb]

johnf3

Can you tell me which dealer you went through to get the KTM parts? I would like to get stateside if possible.

Thanks,

Steve

 

[Kevin31]

How streetable?

Just how streetable is the 520 EXC? I'm looking at the 520 and the 640, I would love a streetable full on MX bike but that may be impossible. What kind of highway crusing speed can I expect? Any overheating problems? Give me some info guys. Thanks..

 

[Buckholz]

Geeze, my last three KTM380exc's have been street legalized with only about $50 worth of stuff. And never been ticketed....

Sure do like AZ.

 

[predatorv125]

Hope you all dont mind me resurecting this thread.

Hope you all dont mind me resurecting this thread.
Any one know if all these parts or kit to make a 520 exc street legal are still available? i dont see any of them on the english version of stega racing?

 

[rulingtheroost]

talk about raising the dead ! go to ktmworld they have on line parts diagram for the euro bikes street legal roost on