Same bike same problem. I take it in tomarrow to get it fixed, only have 70 miles on it. Good thing for warranties. They told me it could be caused by the jetting or from giving it gas while starting. I don't know. Hopfully they can put in the '02 gear. good luck
I just bought my first KTM. It's a 2005 525 exc. I took it out yesterday for its first ride,great ride, but it had a problem over heating. Is there a problem with over heating with these bikes and if so what can I do about it.