KTM SX 150 from 2010 to 2017 Plastic Retrofit

jbstaten
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jbstaten 3/8/2019 1:21pm
3/8/2019 1:21pm
Thanks for the advice. I have everything except the seat, sub-frame, and computer/battery box which are on order. Will start new thread to update when I make some progress.
jbstaten
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jbstaten 5/1/2019 12:05pm
5/1/2019 12:05pm
Balzabubinas wrote:
Update - finished welding brackets. Mod list: Make new side brackets; Make sub-frame extending bracket; Relocate gas tank pin; Heat form gas tank to fit frame...
Update - finished welding brackets. Mod list:
Make new side brackets;
Make sub-frame extending bracket;
Relocate gas tank pin;
Heat form gas tank to fit frame pillar;
Make carb extender;
Shorten silencer pipe to fit subrame mount;

After all mods everyting lines up really nice, even radiator mounting points lines up.









Did you mig or tig weld these brackets to the Chromoly frame? I've heard mixed opinions about mig welding chromoly. I mig welded the tank post on before I heard anything about this. I'm about ready to weld the subframe brackets on now. Thanks!
Balzabubinas 5/1/2019 12:18pm
5/1/2019 12:18pm Edited Date/Time 5/1/2019 12:20pm
Balzabubinas wrote:
Update - finished welding brackets. Mod list: Make new side brackets; Make sub-frame extending bracket; Relocate gas tank pin; Heat form gas tank to fit frame...
Update - finished welding brackets. Mod list:
Make new side brackets;
Make sub-frame extending bracket;
Relocate gas tank pin;
Heat form gas tank to fit frame pillar;
Make carb extender;
Shorten silencer pipe to fit subrame mount;

After all mods everyting lines up really nice, even radiator mounting points lines up.









jbstaten wrote:
Did you mig or tig weld these brackets to the Chromoly frame? I've heard mixed opinions about mig welding chromoly. I mig welded the tank post...
Did you mig or tig weld these brackets to the Chromoly frame? I've heard mixed opinions about mig welding chromoly. I mig welded the tank post on before I heard anything about this. I'm about ready to weld the subframe brackets on now. Thanks!
MIG welded, make sure to pentrate weld through and you will be fine, it's not critical point to worry about - I already tested it Smile Oh and dont grind off weld all the way, I used dremel to grind a bit off to make it smooth
ev00125sx
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ev00125sx 5/29/2019 6:37pm
5/29/2019 6:37pm
Balzabubinas wrote:
My firend got 2017 model and he parted it out for maintaineance, so I thought it might be a chance to see how things fit to...
My firend got 2017 model and he parted it out for maintaineance, so I thought it might be a chance to see how things fit to my 2010 model.
Started mocking up how everything lines up - looking good, will need few mods obviously. Front fender fits with bracket so there's no big deal at front.
Ordered tank, subframe, seat, airbox - will update when I make progress.


Question about the front fender.. which bracket are you using/talking about? I have a 2015 125sx and I need a new front fender, thinking about getting it and a number plate as well!

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baz250uk
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baz250uk 7/3/2020 11:31pm
7/3/2020 11:31pm


2
baz250uk
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baz250uk 7/3/2020 11:31pm
7/3/2020 11:31pm
I was inspired after seeing this post so gave it a go myself happy with the result
Balzabubinas 7/3/2020 11:43pm
7/3/2020 11:43pm
baz250uk wrote:
I was inspired after seeing this post so gave it a go myself happy with the result
Nice job mate! How hard was gas tank to fit right? Did you made any progress on airbox to carb connection?
Glad to see this retrofit working.
baz250uk
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baz250uk 7/3/2020 11:52pm
7/3/2020 11:52pm Edited Date/Time 7/3/2020 11:52pm
baz250uk wrote:
I was inspired after seeing this post so gave it a go myself happy with the result
Balzabubinas wrote:
Nice job mate! How hard was gas tank to fit right? Did you made any progress on airbox to carb connection? Glad to see this retrofit...
Nice job mate! How hard was gas tank to fit right? Did you made any progress on airbox to carb connection?
Glad to see this retrofit working.
I got a sxf tank so had to modify it quite a bit I ended up using jb weld which worked perfectly with no leaks on the look out for a sx one tho. I relocated the stub and just bolted it down and plastics all lined up with rads so quite easy I’m currently using my original air box took a bit of trimming and sealing as can not find a 2016 one
baz250uk
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baz250uk 7/3/2020 11:52pm
7/3/2020 11:52pm
Balzabubinas 7/3/2020 11:59pm
7/3/2020 11:59pm Edited Date/Time 7/4/2020 12:01am
baz250uk wrote:
I was inspired after seeing this post so gave it a go myself happy with the result
Balzabubinas wrote:
Nice job mate! How hard was gas tank to fit right? Did you made any progress on airbox to carb connection? Glad to see this retrofit...
Nice job mate! How hard was gas tank to fit right? Did you made any progress on airbox to carb connection?
Glad to see this retrofit working.
baz250uk wrote:
I got a sxf tank so had to modify it quite a bit I ended up using jb weld which worked perfectly with no leaks on...
I got a sxf tank so had to modify it quite a bit I ended up using jb weld which worked perfectly with no leaks on the look out for a sx one tho. I relocated the stub and just bolted it down and plastics all lined up with rads so quite easy I’m currently using my original air box took a bit of trimming and sealing as can not find a 2016 one
For gas tank did you heat up tunnel area ant pressed against frame to make it fit?
Post some pictures of air boot if it works out - will be great info for others seeking this conversion.
I didnt even thought about using 2010 air boot plastic with boot.
What I did to make it fit is heat up and bend plastic airbox, not the rubber boot cuz it wont reshape (thermoset plastic - burns when heated).
baz250uk
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baz250uk 7/4/2020 12:04am
7/4/2020 12:04am Edited Date/Time 7/4/2020 12:10am
Balzabubinas wrote:
Nice job mate! How hard was gas tank to fit right? Did you made any progress on airbox to carb connection? Glad to see this retrofit...
Nice job mate! How hard was gas tank to fit right? Did you made any progress on airbox to carb connection?
Glad to see this retrofit working.
baz250uk wrote:
I got a sxf tank so had to modify it quite a bit I ended up using jb weld which worked perfectly with no leaks on...
I got a sxf tank so had to modify it quite a bit I ended up using jb weld which worked perfectly with no leaks on the look out for a sx one tho. I relocated the stub and just bolted it down and plastics all lined up with rads so quite easy I’m currently using my original air box took a bit of trimming and sealing as can not find a 2016 one
Balzabubinas wrote:
For gas tank did you heat up tunnel area ant pressed against frame to make it fit? Post some pictures of air boot if it works...
For gas tank did you heat up tunnel area ant pressed against frame to make it fit?
Post some pictures of air boot if it works out - will be great info for others seeking this conversion.
I didnt even thought about using 2010 air boot plastic with boot.
What I did to make it fit is heat up and bend plastic airbox, not the rubber boot cuz it wont reshape (thermoset plastic - burns when heated).
Yeah I will do it sits a bit low at the moment so need to mess around with it later the air box is not pretty but can’t see it underneath the panels it’s a bodge for now till I find one I’m out on it tomorrow. I need to cut my pipe for silencer as sits too low did you cut the original? I’ve ordered a 2016 one but won’t get it by tomorrow

I did heat a little then bolted it down it all seemed to line up so left it at that

Do you still have yours?
Balzabubinas 7/4/2020 12:09am
7/4/2020 12:09am
baz250uk wrote:
I got a sxf tank so had to modify it quite a bit I ended up using jb weld which worked perfectly with no leaks on...
I got a sxf tank so had to modify it quite a bit I ended up using jb weld which worked perfectly with no leaks on the look out for a sx one tho. I relocated the stub and just bolted it down and plastics all lined up with rads so quite easy I’m currently using my original air box took a bit of trimming and sealing as can not find a 2016 one
Balzabubinas wrote:
For gas tank did you heat up tunnel area ant pressed against frame to make it fit? Post some pictures of air boot if it works...
For gas tank did you heat up tunnel area ant pressed against frame to make it fit?
Post some pictures of air boot if it works out - will be great info for others seeking this conversion.
I didnt even thought about using 2010 air boot plastic with boot.
What I did to make it fit is heat up and bend plastic airbox, not the rubber boot cuz it wont reshape (thermoset plastic - burns when heated).
baz250uk wrote:
Yeah I will do it sits a bit low at the moment so need to mess around with it later the air box is not pretty...
Yeah I will do it sits a bit low at the moment so need to mess around with it later the air box is not pretty but can’t see it underneath the panels it’s a bodge for now till I find one I’m out on it tomorrow. I need to cut my pipe for silencer as sits too low did you cut the original? I’ve ordered a 2016 one but won’t get it by tomorrow

I did heat a little then bolted it down it all seemed to line up so left it at that

Do you still have yours?
For exhaust I needed to shorten 20mm or so silencer pipe near connection to expansion pipe, but my silencer was HGS with single mounting point. If you have silencer with two mounting points I think you will need more mods than that.
baz250uk
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baz250uk 7/4/2020 12:10am
7/4/2020 12:10am
baz250uk
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baz250uk 7/4/2020 12:14am
7/4/2020 12:14am
Balzabubinas wrote:
For exhaust I needed to shorten 20mm or so silencer pipe near connection to expansion pipe, but my silencer was HGS with single mounting point. If...
For exhaust I needed to shorten 20mm or so silencer pipe near connection to expansion pipe, but my silencer was HGS with single mounting point. If you have silencer with two mounting points I think you will need more mods than that.
Mines the 2008 144 it has a FMF fatty with FMF shorty I’ve bought a standard silencer looking at the length of the pipe should sit perfect and the bracket hopefully lines up with the subframe mounts can’t see why it won’t
Balzabubinas 7/4/2020 12:14am
7/4/2020 12:14am

You can see where i grind off paint and shortened it
Balzabubinas 7/4/2020 12:20am
7/4/2020 12:20am Edited Date/Time 7/4/2020 12:23am
I think if you cut shorty silencer in two spots (before and after bend) it would fit. Cut out that bend, bolt on silencer at angle looks stock, put cut away pipe inside expansion pipe and just trim to fit.
Performance wise it wont affect anything imho
baz250uk
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baz250uk 7/4/2020 12:26am
7/4/2020 12:26am
Balzabubinas wrote:
I think if you cut shorty silencer in two spots (before and after bend) it would fit. Cut out that bend, bolt on silencer at angle...
I think if you cut shorty silencer in two spots (before and after bend) it would fit. Cut out that bend, bolt on silencer at angle looks stock, put cut away pipe inside expansion pipe and just trim to fit.
Performance wise it wont affect anything imho
I will update with photos tonight
baz250uk
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baz250uk 7/4/2020 6:56am
7/4/2020 6:56am
All done! Using the 08 air box is not a good idea I had to cut and add plastic and seal it with foam tape only as I’m out on it tomorrow I will find the correct air box and redo



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Rickyisms 7/17/2020 10:49am
7/17/2020 10:49am
Route that brake line to the inside of the fork.
1
baz250uk
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baz250uk 7/17/2020 11:14am
7/17/2020 11:14am
Rickyisms wrote:
Route that brake line to the inside of the fork.
I’ve never noticed that I will do
keir.newton 7/24/2021 5:23pm
7/24/2021 5:23pm
baz250uk wrote:
All done! Using the 08 air box is not a good idea I had to cut and add plastic and seal it with foam tape only...
All done! Using the 08 air box is not a good idea I had to cut and add plastic and seal it with foam tape only as I’m out on it tomorrow I will find the correct air box and redo



How did the 2017 air box fit up (if you managed to find one)
I also have a 2008 125 sx and am wanting to do this. How did the carb line up and how difficult was it to make the subframe bracket
walkerdeloach 1/4/2023 5:10am
1/4/2023 5:10am

Hate to bump an old thread but absolutely love it! I’m in the Process of doing this with my 08 200. 
I’ve got a couple questions though:

1) any tips to heating the gas tank? Very nerve racking to do this to a brand new $300 tank

2) also how did you mount up the front fender. I’ve got one but the holes don’t align. Any dimensions on a bracket? I’d rather fab one up but not sure what all you did to get it to mount. 
 

Sorry for the ramble, great work!

cody16'ktm250 9/6/2023 8:39pm
9/6/2023 8:39pm
Balzabubinas wrote:
Update - finished welding brackets. Mod list: Make new side brackets; Make sub-frame extending bracket; Relocate gas tank pin; Heat form gas tank to fit frame...
Update - finished welding brackets. Mod list:
Make new side brackets;
Make sub-frame extending bracket;
Relocate gas tank pin;
Heat form gas tank to fit frame pillar;
Make carb extender;
Shorten silencer pipe to fit subrame mount;

After all mods everyting lines up really nice, even radiator mounting points lines up.









Hey man I'm try to do a conversion my self just wondering if you might have the measurements of the tank mount and sub frame brackets just before I cut any thing of my frame.

Thanks

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