2013 KTM 150sx Gulf FINISHED

Cooper 688
Edited Date/Time 6/14/2021 5:23pm
We've had these 150s from new - hands down the most fun bikes we've ever owned.

Eventually these dirt bikes became more dirt than bike..


We are part way through this rebuild and are mainly focusing on the chassis as the bottom ends still have a little life left in them so we'll do those maybe next year. Powder coating, classic ral2009 orange







We got the Pro Circuit dog bones years ago and really like lower, more stable handling in the rough stuff, they just needed a clean and grease

New forks! ....which meant new smaller axle and wheel spacers. We were stoked to find some of the old CV units with the black coatings. Never had suspension like this before...man these things are beautiful Woohoo


We couldn't find Trax shocks anywhere and were told WP has discontinued them for the old sx. We were happy that Ohlins can make the Flow shock for our bikes. When they arrived one had a smaller gas reservoir - strange..

After dismantling the Magura clutch master cylinders in preparation for cerakoting, I discovered some flaking of the coating inside both cylinders.The outside didn't look too flash either. I think these units are toast

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JMX82
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JMX82 3/2/2020 5:10am
3/2/2020 5:10am Edited Date/Time 3/2/2020 5:13am
Those are great little bikes. I love my 2013 150SX





4
Cooper 688 3/2/2020 6:14am
3/2/2020 6:14am
Yes, we enjoyed your build thread. Hope your bottom end is still running strong after the disaster. Really like your 2012 cases without the redundant electric start casting.
JMX82
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JMX82 3/2/2020 7:54am
3/2/2020 7:54am
Actually my third gear broke last summer destroying engine cases once again. Luckily it's easy to find salvaged parts for these bikes because there's only minor changes in engine cases from beginning of 2000's. I found a good deal for two good used complete 125 bottom ends for a good price and got the bike going again. I still have the another one on my garage shelf for a spare
Cooper 688 9/12/2020 12:17am
9/12/2020 12:17am
Slowly making progress:



Had a local guy repair some dents but the process removed the black in the badge so I painted it and then using various methods removed it from the high areas. It came out OK.






Calipers finally arrived



Cerakote done by Worx Performance Coatings. They are CRF MCs (11mm), that should provide pucker power Laughing



Just used matt black engine paint on the cases for now, but will cerakote them properly when we split them.








8

The Shop

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BToz
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BToz 9/12/2020 7:36pm
9/12/2020 7:36pm
Wow those are looking really good! Nice work man (x2)
1
Cooper 688 9/12/2020 10:23pm
9/12/2020 10:23pm
Thanks. One of the most satisfying things was getting rid of all the crappy rusty oem bolts and replacing with Titanium.
1
JMX82
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JMX82 9/13/2020 4:01am
9/13/2020 4:01am
Those bikes look great! Keep up the good work
1
Cooper 688 9/13/2020 4:31am
9/13/2020 4:31am
Thanks mate, hope your 150 is still ripping. We've had massive delays this year for obvious reasons but making progress now!
FarleyMX25
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FarleyMX25 9/13/2020 6:34am
9/13/2020 6:34am
Cooper 688 wrote:
Thanks. One of the most satisfying things was getting rid of all the crappy rusty oem bolts and replacing with Titanium.
Where did you source your bolts from?
15tc150
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15tc150 9/13/2020 8:32am
9/13/2020 8:32am
Cooper 688 wrote:
We've had these 150s from new - hands down the most fun bikes we've ever owned. [img]https://p.vitalmx.com/photos/forums/2020/03/02/408031/s1200_thumbnail_IMG_0507.jpg[/img] Eventually these dirt bikes became more dirt than bike...
We've had these 150s from new - hands down the most fun bikes we've ever owned.

Eventually these dirt bikes became more dirt than bike..


We are part way through this rebuild and are mainly focusing on the chassis as the bottom ends still have a little life left in them so we'll do those maybe next year. Powder coating, classic ral2009 orange







We got the Pro Circuit dog bones years ago and really like lower, more stable handling in the rough stuff, they just needed a clean and grease

New forks! ....which meant new smaller axle and wheel spacers. We were stoked to find some of the old CV units with the black coatings. Never had suspension like this before...man these things are beautiful Woohoo


We couldn't find Trax shocks anywhere and were told WP has discontinued them for the old sx. We were happy that Ohlins can make the Flow shock for our bikes. When they arrived one had a smaller gas reservoir - strange..

After dismantling the Magura clutch master cylinders in preparation for cerakoting, I discovered some flaking of the coating inside both cylinders.The outside didn't look too flash either. I think these units are toast

Happens all too often, I love hydro clutches, but after years of abuse, they don’t last, and the simple fact that the inner coating can come off of the sealing surface, I think needs to be addressed, nobody pays that much money to have something so important flake out.
15tc150
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15tc150 9/13/2020 8:37am
9/13/2020 8:37am
Cooper 688 wrote:
Slowly making progress: [img]https://p.vitalmx.com/photos/forums/2020/09/11/448901/s1200_IMG_2408.jpg[/img] Had a local guy repair some dents but the process removed the black in the badge so I painted it and then...
Slowly making progress:



Had a local guy repair some dents but the process removed the black in the badge so I painted it and then using various methods removed it from the high areas. It came out OK.






Calipers finally arrived



Cerakote done by Worx Performance Coatings. They are CRF MCs (11mm), that should provide pucker power Laughing



Just used matt black engine paint on the cases for now, but will cerakote them properly when we split them.








Sorry to say it, but you got the exhausts system backwards, scalvini pipe with a pc r304 silencer, the pc pipes simply do not do this justice on these engines, I have owned every one, the pc 144 pipe is perky till sign off, but absolutely will not hold a gear and keep revving, the pc and fmf 125 pipes are nice, but not a great fit for the powerband, the scalvini offered the best gains, from bottom to top, and actually helped mine revv like a 125 should. My 08 engine is now in my 2015 tc chassis. Scalvini pipe is still on it, albeit i have modded the piping to accept a 250sx silencer, didn’t think it would work, but I was pleasantly surprised when it pulled harder everywhere.
JMX82
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JMX82 9/13/2020 11:34am
9/13/2020 11:34am
Cooper 688 wrote:
Thanks mate, hope your 150 is still ripping. We've had massive delays this year for obvious reasons but making progress now!
Yeah my 150SX is working flawlessly now. I rode it last time couple weeks ago. Such a fun little bike


2
Rickyisms
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Rickyisms 9/13/2020 3:04pm
9/13/2020 3:04pm
Your build is getting me hyped to get back to finishing mine!
1
Cooper 688 9/13/2020 4:19pm
9/13/2020 4:19pm
Cooper 688 wrote:
Thanks. One of the most satisfying things was getting rid of all the crappy rusty oem bolts and replacing with Titanium.
FarleyMX25 wrote:
Where did you source your bolts from?
Mostly from Pro Bolt UK but some of the more specific ones like the M10 engine and shock mounts are from Race Tech Ti. Factory Image Racing do a really nice rear axle nut. Motostuff for sub frame bolts and front axle nut.
Darcy16
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Darcy16 9/17/2020 8:19am
9/17/2020 8:19am
Bikes are looking good. Big fan of the ute too
1
Cooper 688 6/13/2021 4:04am
6/13/2021 4:04am
Finally finished the 150s, they are both pretty much identical, one has slightly stiffer fork and shock springs and longer tip on the Hammerhead shifter but that's about it. And the #560 and #584 numbers? That's the bore and stroke of both bikes Grinning haha. 56mm x 58.4mm.

Would be great if Gulf made castor oil like Maxima 927.

We will put some more photos in the "Bike Check" section.













6
Tomok
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Tomok 6/13/2021 7:44am
6/13/2021 7:44am
Looks Awesome!
2

Pit Row

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BToz
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BToz 6/13/2021 2:45pm
6/13/2021 2:45pm
Oh yeah, I like the look! Honest no bs opinion on the carb? I don’t do lectron and I’ve been curious about the stic. A lot of hype around these..
1
Cooper 688 6/13/2021 5:49pm
6/13/2021 5:49pm
Yeah it's a different look for us but really happy with it. Just got back from the first ride and can report the stic is no joke! Really easy start up, very clean off the bottom and a ridiculous mid to top. I seriously can't imagine this motor running any better - it just revs and pulls so hard. Keep in mind they are new carbs with the JD needle made for the stic.
2
JMX82
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JMX82 6/13/2021 11:45pm
6/13/2021 11:45pm
What kind of jetting are you running? I have 200 main and 45 pilot at the moment and I might need get even bigger main jet judging from spark plug color
Cooper 688 6/14/2021 12:24am
6/14/2021 12:24am
50 pilot, 200 main. I’ll have to check my plug, I guess it could be slightly on the lean side.
2
shuggs
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shuggs 6/14/2021 10:35am
6/14/2021 10:35am
Lovely looking bikes👍
1
Mr. Robinson 6/14/2021 12:06pm
6/14/2021 12:06pm Edited Date/Time 6/14/2021 12:07pm
Cooper 688 wrote:
50 pilot, 200 main. I’ll have to check my plug, I guess it could be slightly on the lean side.
Which tube and air screw settings are you using?

Looks awesome.
1
Cooper 688 6/14/2021 5:23pm
6/14/2021 5:23pm
We're using the 114A tube with the air screw 3.5 turns out.
For 250s STIC recommend the 113A tube.
2

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