2016 KTM 150sx Factory Bike build, porting, engine work, walk around tutorial ,pics, video, etc

Edited Date/Time 12/12/2017 5:32pm
I am going to document the process from start to finish with pics and video laying out how a bike is gone through and cataloging what goes into it to build a professional level, competitive, and RELIABLE race bike. There will be small items like fit and finish, as well as the motor with a porting tutorial, modifications, the whole shabang.

There will be some typical stuff you normally see with a walk around but there will for sure be lots of areas never previously discussed and shown HOW to perform these YOURSELF.

From checking squish, to modifying cases, head mods, trans parts, cyl porting, carb work, the list goes on!

This thread will hopefully have lots of views and input and I will keep updating the thread as I go along.

Alot of these practices that I will be showing can also be applied to your bike too, some of the processes may be a little different but the theory is the same!

Here is pic and step one.



It will take a while to do b/c I have other projects going on but please be patient, I intend to do a dyno run(s), to see in stock form with stock jetting what this motor does and go from there.

I hope you all can enjoy this thread and learn as well as contribute to the post in a positive manner!

There are many mod shops out there and everyone has a different way of doing what they do, I will be showing you mine.

thx all! Joshua, aka, JBoneMotorworks

ps- sorry for the link the the other site but tVital wont let me add a photo yet? I had to embed it. Maybe b/c I am a new member?
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12/10/2015 5:08am
this dude does AMAZING work! a ktm "specialist" forsure! this is gonna be a great thread!
Markee
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12/10/2015 5:10am Edited Date/Time 12/10/2015 5:11am
Joshua, Can't wait man!

At the moment i'm at the point to start porting and doing case mods. Have a 250sx motor on the table right now for a top end and setting squish.
RussB
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12/10/2015 6:06am
Wow awesome, really looking forward to this!
I have an 08 RM250 that I want to do some work on and I can see this being very useful.

Are you also going to cover things such as setting ignition timing and the effect retarding/advancing has?

The Shop

imoto34
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12/10/2015 7:32am
I am going to document the process from start to finish with pics and video laying out how a bike is gone through and cataloging what...
I am going to document the process from start to finish with pics and video laying out how a bike is gone through and cataloging what goes into it to build a professional level, competitive, and RELIABLE race bike. There will be small items like fit and finish, as well as the motor with a porting tutorial, modifications, the whole shabang.

There will be some typical stuff you normally see with a walk around but there will for sure be lots of areas never previously discussed and shown HOW to perform these YOURSELF.

From checking squish, to modifying cases, head mods, trans parts, cyl porting, carb work, the list goes on!

This thread will hopefully have lots of views and input and I will keep updating the thread as I go along.

Alot of these practices that I will be showing can also be applied to your bike too, some of the processes may be a little different but the theory is the same!

Here is pic and step one.



It will take a while to do b/c I have other projects going on but please be patient, I intend to do a dyno run(s), to see in stock form with stock jetting what this motor does and go from there.

I hope you all can enjoy this thread and learn as well as contribute to the post in a positive manner!

There are many mod shops out there and everyone has a different way of doing what they do, I will be showing you mine.

thx all! Joshua, aka, JBoneMotorworks

ps- sorry for the link the the other site but tVital wont let me add a photo yet? I had to embed it. Maybe b/c I am a new member?
This should be good. You being a new member should not have anything to do with uploading a pic. Maybe try to save it and upload it instead of embedding.
12/10/2015 7:44am
russB- yes, although there is really only a few deg back and forth you can go, my exp has led me to believe that is has very little effect on the two strokes by advancing or retarding it alot.

4 strokes seem to have the best response in advancing degrees of cam rotation and advancing ign via EFI, or map, etc.

Im gonna start from the airbox and move towards the front!
CrGuy2T
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12/10/2015 8:05am Edited Date/Time 12/10/2015 8:06am
Should be a great build.
JMX82
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12/10/2015 11:06am
I am going to document the process from start to finish with pics and video laying out how a bike is gone through and cataloging what...
I am going to document the process from start to finish with pics and video laying out how a bike is gone through and cataloging what goes into it to build a professional level, competitive, and RELIABLE race bike. There will be small items like fit and finish, as well as the motor with a porting tutorial, modifications, the whole shabang.

There will be some typical stuff you normally see with a walk around but there will for sure be lots of areas never previously discussed and shown HOW to perform these YOURSELF.

From checking squish, to modifying cases, head mods, trans parts, cyl porting, carb work, the list goes on!

This thread will hopefully have lots of views and input and I will keep updating the thread as I go along.

Alot of these practices that I will be showing can also be applied to your bike too, some of the processes may be a little different but the theory is the same!

Here is pic and step one.



It will take a while to do b/c I have other projects going on but please be patient, I intend to do a dyno run(s), to see in stock form with stock jetting what this motor does and go from there.

I hope you all can enjoy this thread and learn as well as contribute to the post in a positive manner!

There are many mod shops out there and everyone has a different way of doing what they do, I will be showing you mine.

thx all! Joshua, aka, JBoneMotorworks

ps- sorry for the link the the other site but tVital wont let me add a photo yet? I had to embed it. Maybe b/c I am a new member?
Here is the missing photo:



I will be following this thread closely

yak651
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12/10/2015 12:05pm
Subscribed!
KTMShane699
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12/10/2015 12:18pm
Welcome JBone. Can't say enough positive about his KTM work. Super knowledgable, and all around good dude. Used to race together "back in the day" and are friends outside of the track...stand up guy. Oh yeah, and he gets around okay on a dirt scooter!

There's always a level of skepticism when some people talk. But when JBone shares some insight, we all just might gain some nuggets of knowledge.

Shane
OR Racer46
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12/10/2015 5:23pm
Thank you for taking time to help and educate us. I look forward to this build. I have a 15 350. When you are done.
Bruce372
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12/12/2015 3:13pm
Is this the same jbone that used to post on dirt rider net a few years ago under a similar name??
Drakep2
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12/13/2015 3:52pm
Super Subscribed! I love stuff like this Smile
12/17/2015 3:29pm
Here is a left side pic of the airbox, gonna remove that white plastic tab and use some foam to get a little more air in there while keeping out the debris. The following pics after this are from around the seat and under the seat where again so foam will be put to keep out mud and water.
KTM send some plastic flaps that they would like you to use but I like to keep the airway open.




cable
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12/19/2015 8:30pm
can you throw it on a scale with a pic?
colintrax
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12/25/2015 8:59pm
I'm dying to see this finished
12/26/2015 5:22am
here is a graphics rendering, keep in mind there will be a black gripper seat all around with orange stripes just on the top.

The company I am working with is Limited Decal, it is a family owned operation and they have the best printing I have seen. www.limiteddecal.com

I have lost so much

time on this with the Holidays!
1/17/2016 2:15pm







here are some pics of the airbox. it shares the same one as the 250f which has the battery...i marked and removed some plastic to get better airflow and then topped off the top with a removable foam piece.
yak651
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1/17/2016 4:25pm
Good idea, plus make cleaning airbox easier!

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