death wobble
Hi Scott,when I bought my 04 525 new it too had this problem,it would wobble at 80kph while riding down my street[the postmans honda ct110 handled better] and in the dirt at times it would violently shake its head almost to the point of throwing me over the bars it was that bad,my mates would ride it and say "great engine but crap handling".
Also when riding slowly over rocks in first gear I could actually hear the front knobby making chirping sounds on the rocks,so in other words the forks were not initially compressing.
I would often crash while going slow due to the harshness of the forks as the front end would often suddenly wash out from under me.
The front always felt light and not planted firmly.
I did a Cape York ride and the Tour Guide rode it,made many adjustments to the rebound and dampening,rode it again and handed it back to me shaking his head and told me to contact a suspension specialist.
After reading dirt bike mag reviews with similar reports I realized I had bought a bike that was renowned for its evil handling and it was not just mine.
I even had the Dealer ask me If I had fixed mine as he had another guy purchase one and was complaining about the handling.
It took money and time but here is how I fixed it.
Australian suspension guru Terry Hay sold me a set of BRP 17 mm offset triple clamps and also a different pin that fits inside the rear shock[later adopted by KTM on following models]and I could then ride down the street without it wobbling but the problems still persisted in the dirt although not as bad.
I then fitted lighter rate Eibach fork springs to suit my weight and Gold Valves as well, this also improved it also but it was still not fully fixed.
I then fitted a Scotts steering damper which helped tame the wobbling but it still was not right as it still would wash out from under me.
I then had a local suspension guy target the initial part of the stroke in the forks to make it softer and it is now fixed.
So I guess it was down to geomentary and the forks being too stiff.
And to any 04 owners who say their bike is fine than your lucky,I was not.
I hope all this helps, Baz.
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