JUST ANOTHER 2016 KTM 250SXF CHASSIS KX500 ENGINE CONVERSION GONE MAD!

Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
7/24/2019 12:45pm
Took it for my first test ride last night.
I'm very impressed with this bike.
A little fine tuning left and this thing will be incredible...


6
Zerofear66
Posts
1081
Joined
4/27/2017
Location
Anaheim, CA, USA
7/24/2019 1:11pm
As soon as the Ti reaches temp, it colors. You don't have to keep it at that temp. In fact, keeping it at temp will not...
As soon as the Ti reaches temp, it colors.
You don't have to keep it at that temp.
In fact, keeping it at temp will not change the color at all...
Only going up in temp will change the color.
I'm not sure that it would aneal that quick.. Or at the temps I can achieve.
Some research is in order :-)
Re-cored to a larger diameter, colored, modded to fit, and assembled.
Ready to mount.



Beautiful!
Now send it to FMF so they can copy it for the rest of us.
Please and thank you 😃
1
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
7/24/2019 6:20pm
As soon as the Ti reaches temp, it colors. You don't have to keep it at that temp. In fact, keeping it at temp will not...
As soon as the Ti reaches temp, it colors.
You don't have to keep it at that temp.
In fact, keeping it at temp will not change the color at all...
Only going up in temp will change the color.
I'm not sure that it would aneal that quick.. Or at the temps I can achieve.
Some research is in order :-)
Re-cored to a larger diameter, colored, modded to fit, and assembled.
Ready to mount.



Zerofear66 wrote:
Beautiful!
Now send it to FMF so they can copy it for the rest of us.
Please and thank you 😃
FMF doesn't need the info.
They can make them at any time.
What prevents them from doing so is the amount of orders they are likely to get.
Would you be doing a conversion or would this be for a KX500 standard chassis?
Zerofear66
Posts
1081
Joined
4/27/2017
Location
Anaheim, CA, USA
7/24/2019 7:06pm
As soon as the Ti reaches temp, it colors. You don't have to keep it at that temp. In fact, keeping it at temp will not...
As soon as the Ti reaches temp, it colors.
You don't have to keep it at that temp.
In fact, keeping it at temp will not change the color at all...
Only going up in temp will change the color.
I'm not sure that it would aneal that quick.. Or at the temps I can achieve.
Some research is in order :-)
Re-cored to a larger diameter, colored, modded to fit, and assembled.
Ready to mount.



Zerofear66 wrote:
Beautiful!
Now send it to FMF so they can copy it for the rest of us.
Please and thank you 😃
FMF doesn't need the info. They can make them at any time. What prevents them from doing so is the amount of orders they are likely...
FMF doesn't need the info.
They can make them at any time.
What prevents them from doing so is the amount of orders they are likely to get.
Would you be doing a conversion or would this be for a KX500 standard chassis?
It's for this little gem
03 KX500
1

The Shop

Zerofear66
Posts
1081
Joined
4/27/2017
Location
Anaheim, CA, USA
7/24/2019 7:19pm
As soon as the Ti reaches temp, it colors. You don't have to keep it at that temp. In fact, keeping it at temp will not...
As soon as the Ti reaches temp, it colors.
You don't have to keep it at that temp.
In fact, keeping it at temp will not change the color at all...
Only going up in temp will change the color.
I'm not sure that it would aneal that quick.. Or at the temps I can achieve.
Some research is in order :-)
Re-cored to a larger diameter, colored, modded to fit, and assembled.
Ready to mount.



Zerofear66 wrote:
Beautiful!
Now send it to FMF so they can copy it for the rest of us.
Please and thank you 😃
FMF doesn't need the info. They can make them at any time. What prevents them from doing so is the amount of orders they are likely...
FMF doesn't need the info.
They can make them at any time.
What prevents them from doing so is the amount of orders they are likely to get.
Would you be doing a conversion or would this be for a KX500 standard chassis?
It's for this little gem
03 KX500
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
7/24/2019 8:04pm
Yours looks great.
Mine is for a KTM chassis with a KX500 engine in it with a one off custom pipe from Growler racing.
Needless to say FMF has no interest in making mine.

Since you have a stock chassis, FMF can make you one just like they did for Sean Collier's KX500.
All the guys at KX Guru Racing have begged FMF to make them for the masses.
But they are not interested unless you know someone who will be willing to buy 50 mufflers.
Here's some pics of Sean's














Zerofear66
Posts
1081
Joined
4/27/2017
Location
Anaheim, CA, USA
7/24/2019 8:39pm
Looks awesome!
I'm surprised we couldn't collectively get 50 orders.
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
7/24/2019 10:23pm
Zerofear66 wrote:
Looks awesome!
I'm surprised we couldn't collectively get 50 orders.
The only thing harder than getting a KX500 guy to change bikes is getting him to spend 300-400 bucks on a muffler...
Its why I had to make my own...
Zerofear66
Posts
1081
Joined
4/27/2017
Location
Anaheim, CA, USA
7/25/2019 7:54am
Zerofear66 wrote:
Looks awesome!
I'm surprised we couldn't collectively get 50 orders.
The only thing harder than getting a KX500 guy to change bikes is getting him to spend 300-400 bucks on a muffler... Its why I had...
The only thing harder than getting a KX500 guy to change bikes is getting him to spend 300-400 bucks on a muffler...
Its why I had to make my own...
This is true my friend 😆
1
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
7/30/2019 8:19am
Even though testing has barely begun on the MSV PHI impeller, I'm switching the PHI for the AS3 I had installed.
Even at sub 4500 RPM's it performs the best.
I can't wait for some desert action on this beast..

Stock



AS3



PHI


1
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
8/6/2019 10:30pm
Dyno day!!



Nothing says Commitment like drilling a hole through your custom one off pipe...



Smoke sucker!!


5
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
8/20/2019 7:59am
Ok... Here's a quickie update.
The bike runs amazing.
Jetting was tough due to the unusually small jet sizes required with this exact set up.
In fact I'm waiting for more jets to come in..
In the mean time I have prepped another carb just to be safe.
I have a few loose ends to tie up but nothing major.
The graphics should be here later this week or early next.
I won't be able to post any pics until after the magazine comes out from here on out
I have 4 gallons of fuel ran through it so it could be ready in a few hours once I get the graphics here.
Right now we are waiting for Daryl (MXA Editor) to give us a exact time and date for the photo shoot and test ride.
It's getting very exciting...
3
Zerofear66
Posts
1081
Joined
4/27/2017
Location
Anaheim, CA, USA
8/20/2019 8:03am
That's awesome Mike!
Can't wait to see the article/test.
Definitely a labor of love.
And lots of $$$$$$😃
1
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
8/23/2019 3:35pm
Just received this from Troy at TSR Products yesterday... This is the second one I have had in my hands. The quality, fit and finish are second to none... Looking forward to mounting this up... If you are interested in buying one, contact Troy through his facebook page:

https://www.facebook.com/TSRPRODUCTS/



1
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
8/24/2019 9:35pm
Quickie mock up


3
2F4A
Posts
137
Joined
5/17/2019
Location
NL
8/26/2019 2:37am
Zerofear66 wrote:
Beautiful!
Now send it to FMF so they can copy it for the rest of us.
Please and thank you 😃
FMF doesn't need the info. They can make them at any time. What prevents them from doing so is the amount of orders they are likely...
FMF doesn't need the info.
They can make them at any time.
What prevents them from doing so is the amount of orders they are likely to get.
Would you be doing a conversion or would this be for a KX500 standard chassis?
Zerofear66 wrote:
It's for this little gem 03 KX500 [img]https://p.vitalmx.com/photos/forums/2019/07/24/362423/s1200_20190423_172205.jpg[/img]
It's for this little gem
03 KX500
Looks slick.

I see you are using those GPI rads, are they any good because i might want to give them a shot on my KTM 250 SXF that is running hot from time to time.
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
8/26/2019 6:29am Edited Date/Time 8/26/2019 6:33am
Believe it or not, I decided to go with the stock KTM radiators. They have slightly more capacity than the KX rads and even though I have only tested external engine temps I have seen no issues.

If you are having issues run a 1.8 cap, a MSV impeller, and use Royal Purple's Purple Ice.
Even with stock rads you should notice a significant difference.

If after that you still have issues then you have other troubles....
1
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
8/26/2019 6:59am
And I finally have all the fittings for the E-start vent relocation setup...


2
Bearuno
Posts
5395
Joined
6/28/2014
Location
AU
8/26/2019 9:31am Edited Date/Time 8/26/2019 9:35am
If the vent on yours is the same as mine, the BSP thread can simply be re-tapped with a 10 x 1mm thread ( bicycle derailleur thread size and pitch, by the way) , to take a banjo bolt, and I then took a hose up into the backbone of my frame. Nearly every ride, I go through fordings that would go over the vent on the E start case.

Prior to this E start, for decades now, I've sealed the OEM crank case vents on all of my bikes , and fitted upwards breathers and hoses to keep water out of the electrics - never had an ignition problem on any of my bikes, whilst plenty around me have had the typical rust on the electrics / crap in cases from water sucking, low case vents.

So, did you check the gears in the E start for 'true' - re my posting and video on about page 2 of this thread? I'm interested to see if those Quebecious have produced decent gears, yet? They sure as hell didn't give two flying f**k's about their quality, and their customers, when they first made these effing things.
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
8/26/2019 11:27am Edited Date/Time 8/26/2019 11:28am
Bearuno wrote:
If the vent on yours is the same as mine, the BSP thread can simply be re-tapped with a 10 x 1mm thread ( bicycle derailleur...
If the vent on yours is the same as mine, the BSP thread can simply be re-tapped with a 10 x 1mm thread ( bicycle derailleur thread size and pitch, by the way) , to take a banjo bolt, and I then took a hose up into the backbone of my frame. Nearly every ride, I go through fordings that would go over the vent on the E start case.

Prior to this E start, for decades now, I've sealed the OEM crank case vents on all of my bikes , and fitted upwards breathers and hoses to keep water out of the electrics - never had an ignition problem on any of my bikes, whilst plenty around me have had the typical rust on the electrics / crap in cases from water sucking, low case vents.

So, did you check the gears in the E start for 'true' - re my posting and video on about page 2 of this thread? I'm interested to see if those Quebecious have produced decent gears, yet? They sure as hell didn't give two flying f**k's about their quality, and their customers, when they first made these effing things.
Yes, when you posted that video I was shocked.
But after checking mine there was no worries.
It seems to me that most of the complaints I heard about on the CR500's have been fixed on the KX500.
I did upgrade the Relay, case bolt length, and vent on mine but it has performed flawlessly up to this point.
I'm not sure how many starts I have done with mine but at least 50... perhaps a lot more as I didn't really count them.

I really appreciate your heads up as well as all the others I received from other users.
Let's just hope it stays that way.

I have spoken to a few other KX500 users and they have had no issues with theirs so maybe they have all the bugs sorted out.

On my vent upgrade I just bought 1/8" NPT thread fittings and it fits perfectly with no issues.
Bearuno
Posts
5395
Joined
6/28/2014
Location
AU
8/27/2019 12:56am
You're right - 1/8" NPT, I had too many stds floating around in my scone after a weekend of going between multiple standards on a job I did. .

I used the banjo bolt and banjo because there was buggerall room to use a NPT elbow on the CR, down by the barrel and case. I also have little enthusiasm for such thread and fittings, and have plenty of 10 x 1mm fittings and tooling.

At least they appear to have rectified one serious issue, of many I found, but they don't give a flying f**k about early customers - customers that gave them money well in advance for what turned out to be dreadfully made products.

I trusted I was going to get a well made, thoroughly engineered product, but got nothing of the sort. In all of my years of producing products - decades - I have never produced a product / modification / job of anything but the highest standard and quality. I expected the same, but, received anything but that.
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
8/27/2019 8:27am
I understand how you feel.
I did a lot of prototype jobs for a machine shop I worked at for a lot of years.
I also did a lot of rebuilding equipment that was 50 plus years old.
When done it has to work first time every time or you will loose a valuable customer and potentially many more.
I'm surprised that early support was so bad on these.
Perhaps we need to design and build a better, more compact system :-)
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
9/4/2019 9:47pm
Ok... I guess this will have to do...


2
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
9/7/2019 9:30pm
The graphics were finalized and approved...


3
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
9/29/2019 8:01am
This will probably be one of the last picture updates I can do until the article comes out.
The photo shoot and test ride will take place in Mid November and likely there will be a 3 month gap until the article comes out Dry
But if something comes up and I can update again I will.
Working on the graphics installation right now.
All I can say is Nic at DeCal Works hit this one out of the park.
I can't wait until the big reveal...
It's been a long build for me... Probably for most of you too Woohoo


4
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
9/29/2019 10:35am
It's been a long long build. Many hours of engine R&D, polishing, fabrication, starting over, frustration, happiness, and now excitement. We are very close to the build off. I wish I could post pics but all I can show is this small teaser..


4
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
10/10/2019 11:11pm
Jason Tanner and I were doing some testing and tuning of the KtX500e.. Jason rolls out of the driveway in 2nd gear. Then he blips the throttle just a touch... Then he flogs it with no clutch work out of the hole. He goes through the gears, turns around and comes back only to tell me that the clutch was slipping. 😲 I had just rode it and I weigh about 70 more lb than Jason so I knew the clutch was fine. We walked out to the street and looked,,, Jason left a black strip for 165 yds down the street... Yes, the bike will be getting new knobs for the build off. And, we de-tuned the engine just a smidge 😃

Sound check
1
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
10/27/2019 9:30am
Something cool showed up to the shop...


3
Sandblaster
Posts
414
Joined
8/11/2016
Location
Eugene, OR, USA
10/28/2019 11:22pm
All I can say is this tank is flawless and I can't wait to mount it up...


3
Zerofear66
Posts
1081
Joined
4/27/2017
Location
Anaheim, CA, USA
10/30/2019 7:48am
All I can say is this tank is flawless and I can't wait to mount it up... [img]https://p.vitalmx.com/photos/forums/2019/10/28/381799/s1200_20191003_102521_resized.jpg[/img]
All I can say is this tank is flawless and I can't wait to mount it up...


Wow!
That's beautiful
How much $😆

Post a reply to: JUST ANOTHER 2016 KTM 250SXF CHASSIS KX500 ENGINE CONVERSION GONE MAD!

The Latest