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

JBoneMotorworks 1/19/2016 6:35am
1/19/2016 6:35am
started on carb,,,this is a torq wing from Thunder Products, I have used these for the last two yrs, seat of the pants says they work and have a great little snap off the bottom...





remove all parts from carb
JBoneMotorworks 1/19/2016 6:37am
1/19/2016 6:37am




start to lay out the install, taking note of the correct direction of the wing and its tabs, etc,,

The Shop

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JBoneMotorworks 1/19/2016 6:40am
1/19/2016 6:40am


Mark the ending tabs and file down as needed to get a nice match
JBoneMotorworks 1/27/2016 9:42am
1/27/2016 9:42am
update- susp getting sent off to PowerBand Racing
linkage lowering arm as well as steering stem stabilizer, and axle set coming in from Ride Engineering
Rekluse core manual and cover on its way
wheels built
traction mx seat cover is here, starting to come together!
Idp57
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Idp57 1/27/2016 10:34pm
1/27/2016 10:34pm
Can't wait for more updates :-)
Bryce Oxley 511 1/29/2016 1:19pm
1/29/2016 1:19pm
JBoneMotorworks wrote:
[img]https://p.vitalmx.com/photos/forums/2016/01/19/120457/s1200_IMG_2092.jpg[/img] Mark the ending tabs and file down as needed to get a nice match


Mark the ending tabs and file down as needed to get a nice match
What does that Carb mod supposed to do??

Do you have any recommendations on suspension work? Im a vet expert and I race Moto and Enduro/XC stuff. My 2016 KTM 150 SX is my first KTM and im not very familiar with the WP suspension or who does the best work.

What pipe/silencer are you going to run?

Have you heard about anyone boring the motor out to a 200??
JBoneMotorworks 1/29/2016 3:43pm
1/29/2016 3:43pm Edited Date/Time 1/30/2016 3:05am
Hello and thanks for your reply! There are a lot of suspension companies out there, I have had a lot of luck with Race Tech and Powerband Racing, ask for the owner Billy.

I run the HGS system, we have tested all types of combos, these fit the best, sound the best, and feel the best!

The carb mod helps the air flow at lower RPMs. It improved throttle response, and overall power.

I am a vet, too, and this may be a great bike to compete, as you can ride it for along time, without getting tired.

This motor can not be converted to a 200, I have done many 200 conversions for customers, but it is with the pre-16 engine design. I may stroke this one to get 155 out of it, but that will depend on clearance issues inside the engine.

Thanks!

usafwx
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usafwx 1/29/2016 8:59pm
1/29/2016 8:59pm
Considering making this my second bike as a 5'10, 155lb, vet C rider. My only concern is the 4CS forks and WP shock. Heard some not great things and also new to KTMs where do I send them off too, I have a good relationship with FC but curious if KTM world or someone else is better to use. Thanks and looking forward to this build.
CarlinoJoeVideo
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CarlinoJoeVideo 1/29/2016 9:07pm
1/29/2016 9:07pm
usafwx wrote:
Considering making this my second bike as a 5'10, 155lb, vet C rider. My only concern is the 4CS forks and WP shock. Heard some not...
Considering making this my second bike as a 5'10, 155lb, vet C rider. My only concern is the 4CS forks and WP shock. Heard some not great things and also new to KTMs where do I send them off too, I have a good relationship with FC but curious if KTM world or someone else is better to use. Thanks and looking forward to this build.
The rear shock is pretty dang good. I've heard the the 4cs forks are pretty good on the 2 strokes. They aren't as bad as people make them sound.

I've had great luck with Factory connection on my 250sx-f. Definitely would recommend them.
usafwx
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usafwx 1/29/2016 9:18pm
1/29/2016 9:18pm
usafwx wrote:
Considering making this my second bike as a 5'10, 155lb, vet C rider. My only concern is the 4CS forks and WP shock. Heard some not...
Considering making this my second bike as a 5'10, 155lb, vet C rider. My only concern is the 4CS forks and WP shock. Heard some not great things and also new to KTMs where do I send them off too, I have a good relationship with FC but curious if KTM world or someone else is better to use. Thanks and looking forward to this build.
CarlinoJoeVideo wrote:
The rear shock is pretty dang good. I've heard the the 4cs forks are pretty good on the 2 strokes. They aren't as bad as people...
The rear shock is pretty dang good. I've heard the the 4cs forks are pretty good on the 2 strokes. They aren't as bad as people make them sound.

I've had great luck with Factory connection on my 250sx-f. Definitely would recommend them.
I've always ridden Yamaha's and the SSS suspension which everyone raves about which makes me apprehensive about the 150's WP suspension and why I'm hesitating dropping $7k on a new bike but this is definitely one I would want in my stable. Thanks for the input.
CarlinoJoeVideo
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CarlinoJoeVideo 1/29/2016 10:30pm
1/29/2016 10:30pm
usafwx wrote:
Considering making this my second bike as a 5'10, 155lb, vet C rider. My only concern is the 4CS forks and WP shock. Heard some not...
Considering making this my second bike as a 5'10, 155lb, vet C rider. My only concern is the 4CS forks and WP shock. Heard some not great things and also new to KTMs where do I send them off too, I have a good relationship with FC but curious if KTM world or someone else is better to use. Thanks and looking forward to this build.
CarlinoJoeVideo wrote:
The rear shock is pretty dang good. I've heard the the 4cs forks are pretty good on the 2 strokes. They aren't as bad as people...
The rear shock is pretty dang good. I've heard the the 4cs forks are pretty good on the 2 strokes. They aren't as bad as people make them sound.

I've had great luck with Factory connection on my 250sx-f. Definitely would recommend them.
usafwx wrote:
I've always ridden Yamaha's and the SSS suspension which everyone raves about which makes me apprehensive about the 150's WP suspension and why I'm hesitating dropping...
I've always ridden Yamaha's and the SSS suspension which everyone raves about which makes me apprehensive about the 150's WP suspension and why I'm hesitating dropping $7k on a new bike but this is definitely one I would want in my stable. Thanks for the input.
Ohhhh yeah maybe you'll notice more of a difference from the SSS stuff. Maybe see if you can test out a buddies bike?

Why not stick with blue bikes and get a YZ and 144 kit?
usafwx
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usafwx 1/29/2016 10:51pm
1/29/2016 10:51pm
CarlinoJoeVideo wrote:
Ohhhh yeah maybe you'll notice more of a difference from the SSS stuff. Maybe see if you can test out a buddies bike? Why not stick...
Ohhhh yeah maybe you'll notice more of a difference from the SSS stuff. Maybe see if you can test out a buddies bike?

Why not stick with blue bikes and get a YZ and 144 kit?
I also thought about picking up another 125 and doing the 144 kit as well. Something about having a KTM in the stable is appealing though. Yep love the SSS stuff, so agreeable and forgiving. Just got a good offer on the 150SX since its winter here and sales are slow. Don't know anyone with one, lol. Live in the NE/dirty jersey.
Motofinne
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Motofinne 1/30/2016 1:23am
1/30/2016 1:23am
CarlinoJoeVideo wrote:
Ohhhh yeah maybe you'll notice more of a difference from the SSS stuff. Maybe see if you can test out a buddies bike? Why not stick...
Ohhhh yeah maybe you'll notice more of a difference from the SSS stuff. Maybe see if you can test out a buddies bike?

Why not stick with blue bikes and get a YZ and 144 kit?
usafwx wrote:
I also thought about picking up another 125 and doing the 144 kit as well. Something about having a KTM in the stable is appealing though...
I also thought about picking up another 125 and doing the 144 kit as well. Something about having a KTM in the stable is appealing though. Yep love the SSS stuff, so agreeable and forgiving. Just got a good offer on the 150SX since its winter here and sales are slow. Don't know anyone with one, lol. Live in the NE/dirty jersey.
You could always do the 4CS to SSS conversion? There should be a thread about that here somewhere!
JBoneMotorworks 1/30/2016 3:08am
1/30/2016 3:08am
PowerBand Racing, ask for Billy, he is the owner, tell him JBone sent ya....the shock is not bad really just not enough rebound dampening imo...the forks need work, he does a showa mid-valve mod that relieves the harsh build up and has better dampening ability.

Pit Row

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Markee
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Markee 2/1/2016 5:47am
2/1/2016 5:47am
Where did you get the foam?

Would like to try that torque wing, but damn, 100 bucks?
Pirate421
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Pirate421 2/6/2016 4:28pm
2/6/2016 4:28pm
Sweet build. I'm moving back home to Mass from Texas in a few months so I will have to come check out your shop if it's open. I just happen to have a ktm 2 stroke that we may have to look at haha Cool
ratonmacias
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ratonmacias 2/15/2016 8:50pm
2/15/2016 8:50pm
did you run the bike on the dyno before the airbox and carb mods?
JBoneMotorworks 2/16/2016 2:33am
2/16/2016 2:33am
no, I thought about it and it would have been too expensive to do multiple dyno runs with it stock, then airbox/carb mods, then with the engine work, etc.

So I am going to to do a few runs with this bike properly jetted, the carb mod, and the airbox mod to see where it is at. There are some numbers floating around the internet claiming about 42 hp bone stock. This number can vary, it is more likely to be 40 or so. I am hoping to get a strong 42 out if this "superstock" set up with 93 octane. This would represent a kind of real world scenario for the masses on pump gas. Not everyone has access to race gas or can afford it.

After that, I am going to do some runs with the pipe combo, engine work, fuel, the whole deal to get a representation of what the motor can do RELIABLY. Many tuners out there can get great hp gains but the reliability goes down. My goal is to get this to 47hp but have great reliability, torq way up, and a wide powerband so it is usable to alot of riders.

thx!

Pirate421
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Pirate421 2/16/2016 7:56am
2/16/2016 7:56am
If you can get a reliable 45hp out of that 150 then there would be just about no reason for any amateur, vet, or guy like me who races for fun, not to buy a 150 if they are considering or questioning the bikes ability over a 250f. That's great
ratonmacias
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ratonmacias 2/16/2016 8:05am
2/16/2016 8:05am
wow quite good numbers. thats 90's 250 smoker hp.
JBoneMotorworks 2/16/2016 10:05am
2/16/2016 10:05am
It is aggressive but I know for a fact the some Renegade SX2 (lead/oxy), fuel is good for about 2hp on a dyno..so if I can get this stock to 42, add two with fuel, and get another 2 hp out of the head, cases, pipe, lectron, and ignition, I will be around 47hp.
Its a goal, I gotta try, if not at least I can show the curves and improvements!
Phillip_Lamb
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Phillip_Lamb 2/16/2016 1:00pm
2/16/2016 1:00pm
Pirate421 wrote:
If you can get a reliable 45hp out of that 150 then there would be just about no reason for any amateur, vet, or guy like...
If you can get a reliable 45hp out of that 150 then there would be just about no reason for any amateur, vet, or guy like me who races for fun, not to buy a 150 if they are considering or questioning the bikes ability over a 250f. That's great
you have to take into accoutn what reliable is. MXA latest issue tested out a full factory type build yz125 with motor built by chad watts. Engine was powerful but a top end only lasted 4 hrs.

Im really interested in the actual gains in percentage ( as numbers can be fudged, not calling any bs but they can be misleading) and how long the engine lasts putting out that much hp
Pirate421
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Pirate421 2/16/2016 1:09pm
2/16/2016 1:09pm
True. But as a vet rider of a 250sx I can get a safe 50hrs out of a top end and I'm betting most could get 20-30 hrs out of a 150. I'll take that all day long over 50hrs on a 250f

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