KX Riders
Maintenance & Technical => KX500 Steel Frame Conversion (SFC) => Topic started by: Toom038 on October 15, 2013, 07:34:59 AM
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I have been lurking and gathering info on here for awhile now. Thanks to everyone that has helped so far. I'm sure I will need more very soon! I'm past the point of no return since I just sold the 450 motor so I thought I would share. Finally got the K5 motor mostly finished, just waiting on the head. She will be going to the fabricator this weekend. Will post more pics then. (http://i555.photobucket.com/albums/jj442/Toom038/photo1-1.jpg) (http://s555.photobucket.com/user/Toom038/media/photo1-1.jpg.html)
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cant wait to see the ready bike... but you should use whit or black plastics and no ktm-orange ... :wink:
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I saw some pics of a white KTM with a cr 500 motor. Looked sharp. But I doubt it will be in the budget.
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Can't wait to see this . Keep the pictures coming :-D
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I really like it...a lot, ive seen a few and have been thinking of switching to a ktm300 ....age and the decline of ability has me leaning twards a more manageable bike....it would be great to get the best of both worlds nice work brother.
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I saw some pics of a white KTM with a cr 500 motor. Looked sharp. But I doubt it will be in the budget.
i know also a red one with honda-graphics made for the ktm-plastics ...
we all didnt have this ammount of money, that we can do all like we want to do.. :wink: some thinks need its time on the way to the finish.. :-D
i had build my kx500sf only from new and used spare parts, found on ebay... that was the second idea on this project : not to butcher running bikes for the conversion... :wink:
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http://motocrossactionmag.com/Main/News/ed9988ba-6d72-4193-8bf3-a658940228e9.aspx
nice white one
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Hey Dave, the write up in MXA is what got me started on this. Plus KTM not offering a modern big bore. Got the head put on today. Thanks Larry for the decomp valve. (http://i555.photobucket.com/albums/jj442/Toom038/photo.jpg) (http://s555.photobucket.com/user/Toom038/media/photo.jpg.html) Motor mounts are close. (http://i555.photobucket.com/albums/jj442/Toom038/photo2copy.jpg) (http://s555.photobucket.com/user/Toom038/media/photo2copy.jpg.html)
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Keep up the good work! And keep the pictures coming! :-D
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this pic shows what i thought as i saw the fmf-bike the first time... with the ktm-steel-frame is this conversion way easier as with the other 4stroke-aluminium-frames .. :wink: but everybody should have the bike, what he want to ride... 8-)
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We pretty much got it done now. Mt welding friend had the motor mounts finished in a day. The stock head stays were used with no mods. It took a few hours of cutting cr500 and kx550 FMF pipes to get the bends we needed. We used the kx head and stinger with the cr mid (fat part) section. A lower pipe mount was added to the frame. A cr500 FMF muffler was used. It had to be tweaked also. (Thanks to Motopunk for the pipe info!http://i555.photobucket.com/albums/jj442/Toom038/photo11.jpg) Had to use an older (98) KTM 2 stroke air boot to align with the carb. I mounted the cdi box and coil on the same stock KTM mounts. Very little grinding to get them to fit. Had to make a bracket to attach the rear brake spring since it was originally mounted to the engine. Not pretty but it works and the kicker hides it. The kick starter knuckle rubbed on the frame so I had the remove about 2mm of frame.http://i555.photobucket.com/albums/jj442/Toom038/photo41.jpghttp://i555.photobucket.com/albums/jj442/Toom038/photo10.jpg
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I took it to the track today. It was running a bit lean. I was pinging at about 1/3 throttle. Need to fiddle with the jetting. The track was deep sand. Had no water leaks. But the counter shaft oring was weeping a bit. That was expected since I used one from Ace since the Kawi shop didn't have one. I weighed the bike before and after the swap. Stock was 239 and now it's at 227. I can feel the weight difference just about every where on the track. Especially in the corners. Much more responsive, less sluggish. The stock 450 wanted to stand up in ruts but The KxTM stays in them and rails. The only bad trait I need to try to fix is that the engine wants to surge or run on when chopping the throttle entering turns. I'm hoping correct jetting will help. Won't be able to ride this coming weekend but will post an update when I do.
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What is your current jetting?
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168 main, 58 pilot, stock needle in 3rd air screw 2 out. I'm at sea level running Motul at 50:1
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oh to much honor for my little bit mechanical knowledge... :-D
here is your pic .all you have to do is click here "insert image" and copy the direct link from photobucket in there ...
(http://i555.photobucket.com/albums/jj442/Toom038/photo10.jpg)
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In my sand bike and super moto I run the following:
168 main, 55 pilot, stock needle in 3rd position, with the air screw 1.5 out, I'm at sea level running Motul 800, Non Ethanol 92 at 50:1.
Both bikes run flawless with no ping or high rev at idle.
I suspect that you might have a small air leak...
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In my sand bike and super moto I run the following:
168 main, 55 pilot, stock needle in 3rd position, with the air screw 1.5 out, I'm at sea level running Motul 800 at 50:1.
Both bikes run flawless with no ping or high rev at idle.
I suspect that you might have a small air leak...
+1 on the air leak, do a leak down test....I'm at about 250FT above sea level, and I'm running far leaner jetting than both of you with awesome results...at 50:1 on Motul with a 25% mix of VP-C12 mixed in with 93 octane.
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Thanks. Will do leak test.
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Yes, there was an air leak. Seems I had the seal on the power valve actuating arm in backwards. I took it to the track yesterday and it ran much better. After playing with the air screw and idle adjustment I got rid of the surging and/or run on. This thing is very sensitive to air screw settings. I'm really starting to like this conversion. The 12 pound difference can be felt everywhere. It can be ridden longer, it doesn't wear me out as fast. The lack of weight makes it easier at turn in. Had to soften the compression on both ends 4 clicks and reset the rear sag. I will need to change my riding style a bit. Haven't ridden a smoker since '99 I think. Found myself trying to clear jumps with the throttle instead of speed. Had it nose high a couple of times. With the thumper I could gas it on the faces to clear them. It's kinda scary doing that now when the power valves open. This thing is a beast! And a blast to ride!
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Yes, there was an air leak. Seems I had the seal on the power valve actuating arm in backwards. I took it to the track yesterday and it ran much better. After playing with the air screw and idle adjustment I got rid of the surging and/or run on. This thing is very sensitive to air screw settings. I'm really starting to like this conversion. The 12 pound difference can be felt everywhere. It can be ridden longer, it doesn't wear me out as fast. The lack of weight makes it easier at turn in. Had to soften the compression on both ends 4 clicks and reset the rear sag. I will need to change my riding style a bit. Haven't ridden a smoker since '99 I think. Found myself trying to clear jumps with the throttle instead of speed. Had it nose high a couple of times. With the thumper I could gas it on the faces to clear them. It's kinda scary doing that now when the power valves open. This thing is a beast! And a blast to ride!
awesome...ride on!.....wish I could, little too cold for me today, 25 degrees and light snow :?...not the most desirable riding conditions.
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(http://[URL=http://s808.photobucket.com/user/carl-fee/media/VMX-AU/08KTM-5002T2_zpsf670791d.jpg.html][IMG]http://i808.photobucket.com/albums/zz4/carl-fee/VMX-AU/08KTM-5002T2_zpsf670791d.jpg)[/URL][/img]
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Put a 40MM Smart carb on it and it will run perfect wherever you go. Bolted mine on my KX500 Timbersled snowbike at 5,000 feet adjusted and brought it up the mountain to 10,000 feet and it runs perfect. No more jetting!!!!!!
(http://i.imgur.com/UozKj0t.jpg)
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I want a KXTM now! Thanks guys. Ive always liked KTM ergos and feel (worked at a dealer) Love the 500 just don't like the tank feel. Guess I need to keep an eye out for a KTM roller.
Bike looks factory. Great job. Need video of it slingin dirt :P
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She's for sale now. Craigslist Orlando. Unless I can convince the little woman that I really do need 2 dirt bikes.
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She's for sale now. Craigslist Orlando. Unless I can convince the little woman that I really do need 2 dirt bikes.
only 2??!!
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oh ... :-o ... you could try to tell her, your bike is a rare unique prototype... :-D hope this diamond will come to good hands...
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Hey Toom038 I have a couple questions before you disappear from this site.
1- How did you drill out your engine case? By hand? Machined?
2- How did you make the 6mm spacer for the swingarm pivot bolt?
3- How did you do your motor mounts?
4- Didn't you use a Service Honda Pipe?
5- What type of muffler is the FMF? KTM300?
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Drilled them on a drill press. My welding friend made the spacer. He has a lathe. He also did the motor mounts. Left the stock mounts on the frame and added/welded some steel material for the new ones. I used a New cr5 FMF Gnarly(fat section) and a used FMF gnarly K5 pipe(head pipe and stinger). If I had to do it again and I probably will soon, I would buy the Service pipe. I used a new FMF powercore2 CR5 muffler.
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Drilled them on a drill press. My welding friend made the spacer. He has a lathe. He also did the motor mounts. Left the stock mounts on the frame and added/welded some steel material for the new ones. I used a New cr5 FMF Gnarly(fat section) and a used FMF gnarly K5 pipe(head pipe and stinger). If I had to do it again and I probably will soon, I would buy the Service pipe. I used a new FMF powercore2 CR5 muffler.
Hey thanks toom038,,, I'm doing the Christini ktmkx so your bike was very interesting to me.
I plan to farm out the welding,,, I don't want bird poop welds uglying up my GreenPumpkin.
Great looking bike by the way.