CR500 powered KTM

DOHCFOX · Post by **DOHCFOX** » June 18th, 2008, 5:44 pm

Hey all,

So I recently ran a poll in the AF forum whilst debating over and AF versus KTM (plateable here in WA) project. I decided on the KTM. Here are some initial pics of the swap:

http://picasaweb.google.com/dohcfox/CR5 ... 5620866018

http://picasaweb.google.com/dohcfox/CR5 ... 8343288946

http://picasaweb.google.com/dohcfox/CR5 ... 6901979250

http://picasaweb.google.com/dohcfox/CR5 ... 3545345266

http://picasaweb.google.com/dohcfox/CR5 ... 7598071586

http://picasaweb.google.com/dohcfox/CR5 ... 9628351682

So I need to make some spacers for the swing arm pivot and a mount for the head stay. Otherwise, I've gotten the front and lower mounts welded up and bolts in place. I'm stoked!

JT

dannygraves · Post by **dannygraves** » June 18th, 2008, 5:49 pm

VERY

britincali · Post by **britincali** » June 18th, 2008, 5:51 pm

Thats a bitchin conversion

dannygraves · Post by **dannygraves** » June 18th, 2008, 5:58 pm

dude, you should make a custom strait intake boot since the shock won't be a problem!

DOHCFOX · Post by **DOHCFOX** » June 18th, 2008, 8:53 pm

Thanks! I betcha love my pretty garage too! That fridge used to be a kegerator....but anyways.

I'd love to do a straight intake boot for the motor but unfortunately, or fortunately, the stock KTM 2 stroke boot will mate up nicely with the stock CR500 carb placement, according to my hypothesis.

Next up is welding up the head stay. Or did I already mention that? Shoot, that was 5 beers ago. Such is life.

Regardless, I can't wait to roll this thing out. More pics to come...

JT

ISBB · Post by **ISBB** » June 18th, 2008, 8:57 pm

Now that is thinking outside the box

I LIKE IT!!

fastkart · Post by **fastkart** » June 18th, 2008, 9:22 pm

dannygraves wrote:dude, you should make a custom strait intake boot since the shock won't be a problem!

I bought one of these for my GSS motor. http://www.qrckarts.com/store/index.cfm ... uct_ID=255

Only issue I found is that you may need to open up/match the intake boot to the aluminum. Also, the carb fits very snugly and is almost hard to get in the first few times.

DOHCFOX · Post by **DOHCFOX** » June 18th, 2008, 9:46 pm

fastkart wrote:
dannygraves wrote:dude, you should make a custom strait intake boot since the shock won't be a problem!
I bought one of these for my GSS motor. http://www.qrckarts.com/store/index.cfm ... uct_ID=255

Only issue I found is that you may need to open up/match the intake boot to the aluminum. Also, the carb fits very snugly and is almost hard to get in the first few times.

But otherwise, it fits?

fastkart · Post by **fastkart** » June 18th, 2008, 9:52 pm

Absolutely. I can pull mine off and snap some pics if you want with it on/off.

DOHCFOX · Post by **DOHCFOX** » June 18th, 2008, 9:54 pm

fastkart wrote:Absolutely. I can pull mine off and snap some pics if you want with it on/off.

If you do not mind, that'd be great! I am however waiting to see if a KTM 2 stroke boot matches up with my carb placement. Otherwise, if this setup offers any advantages, I am all ears.

Thanks you!

JT

fastkart · Post by **fastkart** » June 18th, 2008, 9:55 pm

quantum500 · Post by **quantum500** » June 19th, 2008, 6:31 am

These out of the box repower projects are always a little more interesting than the plain jane AF I have a little project I'm in the middle of right now that I need to take some pictures of. Good luck and take your time usually the solution to a problem takes patients and maybe a couple days to get the right solution worked out. Its always more difficult when there is no one out there to ask "How did you do that?"

ISBB · Post by **ISBB** » June 19th, 2008, 2:45 pm

Fastcart where did you get that 90* fitting for the head? and how well does it seal? and how much taller is it than the stock lugs that are on there?

fastkart · Post by **fastkart** » June 19th, 2008, 3:25 pm

ISBB wrote:Fastcart where did you get that 90* fitting for the head? and how well does it seal? and how much taller is it than the stock lugs that are on there?

Thats an XRP brand fitting. It is 1/2 inch pipe thread on the head (had to be drilled and tapped) and converts to a -12 AN which uses 3/4" heater hose. I had Glen @ GSS do the work, so I don't know what he used to plug the other outlet. It is leak free, just make sure you use plenty of thread tape. I should have used more as it will vibrate and move a little, but there are zero leaks.

The top of the fitting sits right at 2 inches from the head.

Here's 2 ways to do the same thing... the first is the picture is how the motor in my previous post is set up... the other is a better way (in my opinion) that my 2nd motor is equipped with.

fastkart · Post by **fastkart** » June 19th, 2008, 3:46 pm

A little explanation on why the 2nd choice is better since I have a spare few minutes... the first option, with the elbow that threads into the head then the straight piece to hook up the hose... unless you start the tap at just the right spot, and have just enough thread tape on it, when the fitting is tight, the outlet will be facing away from the radiator/direction you want the water to flow.

With the second option, you thread in and tighten the adapter (with tape of course) then do the same with the second piece, which makes the 90* bend. The second piece swivels, so you can aim it where you want, then tighten the nut.

ISBB · Post by **ISBB** » June 19th, 2008, 4:20 pm

Im just thinkin for all of the guys having to do some fancy creative stuff for the A/F conversions and me going to be doing one soon a way to avoid modding the tank as much as possible.. Im thinking this combined with a shorty plug should get me pretty damn close to not having to mod the tank hardly at all

Thx for the explanation and info

fastkart · Post by **fastkart** » June 19th, 2008, 4:33 pm

One more quick tidbit about the method I said I preferred... it stands about 3" off of the head, rather than the 2" of the one that is pictured on the motor.

Post by **AlisoBob** » June 19th, 2008, 4:37 pm

ISBB wrote:Im just thinkin for all of the guys having to do some fancy creative stuff for the A/F conversions and me going to be doing one soon a way to avoid modding the tank as much as possible..

My Gen 4 conversion

100hp honda · Post by **100hp honda** » June 19th, 2008, 4:46 pm

damn where did you put that coil bob. back by the airbox?

Post by **AlisoBob** » June 19th, 2008, 5:02 pm

Further back, under the right number plate...

Post by **AlisoBob** » June 19th, 2008, 5:04 pm

DOHCFOX wrote: More pics to come...

JT

Sweet!

DOHCFOX · Post by **DOHCFOX** » June 21st, 2008, 3:38 pm

I cannot believe how well the expansion chamber fits!! This is so un fucking real I'm having a hard time believing it!

http://picasaweb.google.com/dohcfox/CR5 ... 3607299378

http://picasaweb.google.com/dohcfox/CR5 ... 8293680690

http://picasaweb.google.com/dohcfox/CR5 ... 3540930258

87CR500Rider · Post by **87CR500Rider** » June 22nd, 2008, 8:37 am

I almost went this route but found an 01' CR125 roller. A buddy has an 04' 450SX with a grenaded engine. We were thinking about cramming a CR500 engine in it for play riding. Alot cheaper than fixing that 4 stroke for sure.

Acid · Post by **Acid** » June 23rd, 2008, 7:46 am

thats very cool mate

cypher1024 · Post by **cypher1024** » June 26th, 2008, 3:29 am

You know, that spare water outlet could have been plugged with an aluminium slug and used for a decompressor...

Great work so far mate. it looks awesome!

BannedCR500Riders.com

CR500 powered KTM

CR500 powered KTM