Maintenance & Technical > KX500 Steel Frame Conversion (SFC)
07 KTM 250sxf/500kx conversion
hunter:
New guy here, really enjoying the site and learning a crap ton. My conversion started the second I bought the KTM with a blown motor, was hopeing for a simple topend fix but the head was toast. Off to google for alternatives and that's where I found you guys. I have not made it to far yet but have started ordering parts I know I will need.
What I have so far :
2007 KTM 250sxf
3 -1987 KX500 engines (1 Running supposedly, 2 in parts but could have a second running one with piston and rings)
Service Honda kx500af pipe on the way
Need to order/do:
Decomp valve
Hydro clutch actuator
Misc tid bits
Hold ups:
1. Reaming the rear engine mount hole to 17mm. I live in a small town so its hard to find someone who can do this and I wouldn't mind keeping the case oem. I have a few ideas.
-- Have a bushing made for the swing arm holes 17mm OD and 15 ID, would use a Different pivot bolt (maybe one from a earlier year KTM?)
-- I sent allballs a email asking if they could put together a bearing kit for the swing arm that would have a 15mm hole, effectively doing the same as above
2. Exhaust:
-- From what I can tell it seems the KX500af pipe is the best route to start with, but I also assume its not going to just line up. Anyone else use one of these and if so what mods did you have to do to make it work with the KTM frame?
-- Still researching on what muffler to use, hopeing maybe a KTM 300 2stroke one will work maybe different Cone Diameter?
Anyways, this will be a slow moving project as money is the main factor in the way but working on getting that handled the best I can.
dave916:
hi
What your engine/ swingarm clearance both sides?
I Have done 17-15mm bushing {not on ktm} they worked out good they do turn out pretty thin[only 1mm thickness}
On my build 12 mm clearance one side and 2mm other side
One bush ended up a straight sleeve and the other sleeve had 6mm collar and need to be about 3mm longer than swingam bush to slide into the frame /
Changing bearings in swingarm will still leave u with 17mm holes in frame
hunter:
--- Quote from: dave916 on August 16, 2016, 01:00:52 PM ---hi
What your engine/ swingarm clearance both sides?
- I have not checked this as of yet, trying to get the engine in there first with the rear pivot mount and then will cut the old mounts out and mock everything up where the sprockets are aligned.
I Have done 17-15mm bushing {not on ktm} they worked out good they do turn out pretty thin[only 1mm thickness}
On my build 12 mm clearance one side and 2mm other side
One bush ended up a straight sleeve and the other sleeve had 6mm collar and need to be about 3mm longer than swingam bush to slide into the frame /
I assume the 6mm collar was to get the engine offset for the sprockets? I remember reading that somewhere.
Changing bearings in swingarm will still leave u with 17mm holes in frame
Yeah was thinking about that, though maybe some small short bushing for the frame but I am not likeing the idea.
--- End quote ---
Sorry its taken a bit to get back with you. Crazy busy at work.
My answers up in blue, I loved the idea of changing the bearing until you reminded me about the frame. So I think I am back to the bushing idea or just buying a reamer and taking the plunge on the cases then its just a done deal. Bushings are pretty easy for me to get made up, just need to tell my buddy what I need.
dave916:
A quick drawing to let u know what i done / very important that bushing are right length
U dont want to end up with swingarm or motor not tightening properly
The reason for the collar is so u can remove swing arm without removing motor
17by15mm Bushes or in purple :-D
hunter:
Dave,
Seriously appreciate the diagram and all the info. I was talking with my gunsmith today and he said he had adjustable reamers that would make short work of reaming out the hole, done by hand. Now that this could be a option I am leaning that way just to make life simple. Hopeing to get that done this Sunday if all goes well.
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