BannedCR500Riders.com

I've already done 2 ktm to ktm hybrids: http://www.advrider.com/forums/showthread.php?t=662808


I got a good deal on a Craigs list CR5 this weekend and already had a ktm roller in the garage. It should be a simple build






I spent some time tonight making the pivot spacers and getting the sprocket into the correct horizontal alignment.


I threw the rads and pipe on to see if there were going to be any issues. the right rad outlet points in the wrong direction (a 250sx rad should solve it)



The right outlet is perfect


The shock spring to pipe clearance may need some tweaking

I like this, keep the pics coming.....I'm interested to see how this turns out!!

As soon as I bought my KTM i was measuring the cradle for a 500.
The only problem I could see was the shock spring/pipe situation.
Thankfully / unfortunatly, my 4 stroke is still running strong.

Looking forward to seeing this bike finished!

What year- model KTM is it???

blownbillybob wrote:What year- model KTM is it???

It's a 2007 450sxf frame, (07-10 450/505 SXF and XCF frames are the same)

Additionally all ktm frames from 08-10 are identical except for the cradle and length of the downtube... meaning you could do a cradle swap on any of them and it will work.



08 250xcf frame with 04 525exc cradle

nice makes ktms reliable could have cleaned the motor first but mate

gregrobo wrote:nice makes ktms reliable could have cleaned the motor first but mate

ha, since I'm using it as a welding fixture for the mounts i didn't see a need. once the chassis is done I'll start on the motor.

Old mounts cut out and cleaned up


Re-positioned for the 500 engine and welded back in

you gotta love steel ant ya!!! lovely...

I changed to 2t radiators (125sx). They end up working out perfectly w/o any fab.




I'm just waiting on the carb boot and silencer to show up and I can finish the remaining fabrication

Since i'm just waiting on parts to arrive, I decided to clean up the engine

In the process of cleanign i noticed the crank was semi submerged in oil..

crack

I have no idea what this is



monkeys should not have tools, the stator side seal is bottomed out as well


cleaner



some baking 30min @ 300


easy as Pie



On the plus side the cylinder is still on the stock bore. now to see how a ultrasonic cleaner does on the remaining dirt

nice im watching with interest i like the ktms just not the expensive rebuilds on the engines i have seen here thathave hand grenaded

gregrobo wrote:nice im watching with interest i like the ktms just not the expensive rebuilds on the engines i have seen here thathave hand grenaded

Even the expensive engines can be fixed "relatively" cheaply when you shop around for parts

jar944,

I noticed in one of your photos you said "I noticed the crank semi submerged in oil" what exactly do you mean? I am in the process of just putting a new top end on my 2001 engine and I rotate the crank by hand I see oil on the crank also is this not supposed to be like this? New to this engine (previously had KTM 450SXF) just a question since I am not sure.

Brian

Papagyo wrote:jar944,

I noticed in one of your photos you said "I noticed the crank semi submerged in oil" what exactly do you mean? I am in the process of just putting a new top end on my 2001 engine and I rotate the crank by hand I see oil on the crank also is this not supposed to be like this? New to this engine (previously had KTM 450SXF) just a question since I am not sure.

Brian

There should be some residual premix/light oiling on crank. On this one there was about 1/2 quart of trans oil.

The cases are out of the ultrasonic cleaner

before


after




The carb boot and silencer arrived today as well so i can continue with the remaining fabrication

do the KTM 4 strokes have oil or water going in the frame? I'm looking at the pics and see a tube the sticks out on the bottom of the main down tube of the frame where the head is. Is that some kind of water or oil tube that a 4 stroke motor runs?


Great build, are the 2 stroke and 4 stroke frames the same geometry in these yr KTM's or is the 450 frame roomier in the craddle?


i would like to do one of these but looking at used KTM's the bikes are pretty expensive, I guess a guy could get some of the money back selling the parts you don't need. (Motor mainly)

LOVEMYCR500 wrote:do the KTM 4 strokes have oil or water going in the frame? I'm looking at the pics and see a tube the sticks out on the bottom of the main down tube of the frame where the head is. Is that some kind of water or oil tube that a 4 stroke motor runs?


Great build, are the 2 stroke and 4 stroke frames the same geometry in these yr KTM's or is the 450 frame roomier in the craddle?


iwould like to do one of these but looking at used KTM's the bikes are pretty expensive, I guess a guy could get some of the money back selling the parts you don't need. (Motor mainly)

All 07/08+ ktm's have a coolant tube running through the frame. the top rad outlets go into a coupler in the frame that dumps out the bottom.

All the frames from the 125 to the 530 share the same main frame, only the cradle and length of the downtube differ. The 450/505sxf/xcf are a very close fit. the other 450&530 are considerably larger in the front cradle. a 250 4t frame may work as well, but all will work with a cradle swap.

As for prices i've picked 4 of mine up rather cheaply.

The ktm 2t carb boot while not perfect (the angle of the reed boot is not the same as the filter boot) it will work out.

Awesome build! I wanna see more

cleaned up the cases today

hey !!! looks good!!!

been working on my ktm conversion and building a new engine for it also ,can't wait to ge it going ill have to snag the wifes camera and try and get some pics up, just been hell busy with work!!

hey !!! looks good!!!

been working on my ktm conversion and building a new engine for it also ,can't wait to ge it going ill have to snag the wifes camera and try and get some pics up, just been hell busy with work!!

blownbillybob wrote:hey !!! looks good!!!

been working on my ktm conversion and building a new engine for it also ,can't wait to ge it going ill have to snag the wifes camera and try and get some pics up, just been hell busy with work!!

cool post up some pics.

i'm having the same problem with work getting in the way myself

I spent some more time in the garage tonight. I made the final case bushings and the head stay (cut and welded 250sxf stays)

Sweet build, we'll all need a full ride report.