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

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11/20/2017 11:01 AM
Edited Date/Time: 11/20/2017 11:02 AM

So, here it is in the back of the truck and headed 4 hours home...

I have never tried this conversion before so we will see what happens.. :-)

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11/20/2017 11:03 AM

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11/20/2017 12:35 PM

Following!!

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11/20/2017 3:39 PM

Well, good luck.

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11/20/2017 3:46 PM

Got it home... Time for the real work to begin..

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No... I will not be using my SM for a donor Lol...

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11/21/2017 2:05 AM

Will be watching with interest, I'm about to start something similar, putting a ktm380 engine in 2015 250sx frame

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11/21/2017 6:15 AM

vmxracer wrote:

Will be watching with interest, I'm about to start something similar, putting a ktm380 engine in 2015 250sx frame

Jason From JT engine Works and I have discussed the same thing... But it's on the back burner until I get this one done Lol..

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11/21/2017 6:19 AM

Well... This isn't going to work at all... Lol

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11/21/2017 3:55 PM

Just for grins I compared a older 07 KTM 450 frame to the kx500 engine and that would be a much easier conversion... But, I'm hard headed :-)

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11/22/2017 12:37 AM

Sandblaster wrote:

Just for grins I compared a older 07 KTM 450 frame to the kx500 engine and that would be a much easier conversion... But, I'm hard headed :-)

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If you did that 07 chassis you'd be the proud owner of one evil handling machine! Along the line of a TM400

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11/22/2017 1:19 AM

Most wild conversions require cutting and modifying the frame.
Now get to work?

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11/22/2017 1:49 AM

Can you use part of the 07 cradle with the 16 frame?

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11/22/2017 5:37 AM

Sandblaster wrote:

Just for grins I compared a older 07 KTM 450 frame to the kx500 engine and that would be a much easier conversion... But, I'm hard headed :-)

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PTshox wrote:

If you did that 07 chassis you'd be the proud owner of one evil handling machine! Along the line of a TM400

Good thing I'm using the 16 frame :-)

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11/22/2017 5:38 AM

moto9 wrote:

Most wild conversions require cutting and modifying the frame.
Now get to work?

Yes they do Lol....

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11/22/2017 5:39 AM

vmxracer wrote:

Can you use part of the 07 cradle with the 16 frame?

Yes you can :-)

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11/22/2017 5:42 AM

I have the coolest water cooled band saw you have ever seen!!!

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11/22/2017 5:45 AM

The most important thing you should do is swap out the teeth chattering 4cs forks with the old kawasaki open chambers! They will work ten times better! Jk but not really.
Looking forward to seeing it finished.

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11/22/2017 5:46 AM

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That was easy enough..

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11/22/2017 5:48 AM

JWACK wrote:

The most important thing you should do is swap out the teeth chattering 4cs forks with the old kawasaki open chambers! They will work ten times better! Jk but not really.
Looking forward to seeing it finished.

Oh yeah... Still working on that...
I have a set of 11 KX450F forks but I'm looking at something else right now...
Schools still out on that for now..

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11/22/2017 8:00 AM

Sandblaster wrote:

I have the coolest water cooled band saw you have ever seen!!!

Awesome haha

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Greg D.
2018 yz250f

11/22/2017 9:16 AM

Is that one of the two bikes I found for you, or ANOTHER one? Bike pig. laughing

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11/22/2017 9:30 AM
Edited Date/Time: 11/22/2017 9:31 AM

Hmmm...
The pumpkin came from Grantspass OR..
A guy on Facebook had it for sale.
I eventually ended up buying two and shipping one to Canada...
Someone gave me the heads up on the first pumpkin on Facebook... but I can't remember who.. I thought he was in the US.
If it was you, Thanks! Lol

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11/22/2017 4:48 PM

Ok... I did the rough work and Jason came in and did some more clean up.
We are being very careful to remove as little material as possible.
These tubes are thin and we don't want to weaken them and more then required..

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11/22/2017 11:24 PM

You're digging in! That's the only way to do it. It will all work out...kePhoto

keep an eye on the counter shaft sprocket location vs the swing arm pivoit bolt. You want the counter shaft
to be a little bit below the swing arm piviot bolt... )

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11/23/2017 2:30 AM

Why, Why , did you cut the foot peg mount section of the of the swingarm pivot casting???????????????

You've made things so much harder for yourself.

I did such a conversion last year, and I just removed the tubing part of the cradle and made a whole new cradle to go from the cast plates, and then up to (the necessarily higher point to clear the exhaust) downtube.

All it took was less than $60 AUD of 1 1/4" 4130, and the 2 bends to each side of the cradle. I also put in 2 diagonals from the linkage mount / frame cross over much like you'd see on most steel frames.

I always set the Counter Shaft center of any 'hybrid' I make at the same height as the original engine (well, unless it's too bloody high as std, when you factor in the huge torque of a 500 2t) .Too many people end up placing that center too high, just to make 'ancillaries' easier to accommodate, but it's a great way to really, really stuff up your suspension and handling.

The Center of the CS and SA Pivot Center is dictated by the engine (but you can get fancy with offset case inserts for the SA pivot bolt to go through) , but I've found usually less than 5mm difference, as designers had long since learned that as small a distance as possible was the go.

I hope it works out for you - my mate that I did the KX500 / 16 SXF Hybrid for loves it, and it was an easy job to do. Being steel, with far smaller frame sections, makes things far simpler than an AF.

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11/23/2017 3:14 AM

vmxracer wrote:

Will be watching with interest, I'm about to start something similar, putting a ktm380 engine in 2015 250sx frame

First of all where did you find a 380 Engine in Australia?!?! Second of all do you know of another?!?!

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Instagram @_yabba_dabba_dont_


11/23/2017 6:38 AM

Bearuno wrote:

Why, Why , did you cut the foot peg mount section of the of the swingarm pivot casting???????????????

You've made things so much harder for yourself.

I did such a conversion last year, and I just removed the tubing part of the cradle and made a whole new cradle to go from the cast plates, and then up to (the necessarily higher point to clear the exhaust) downtube.

All it took was less than $60 AUD of 1 1/4" 4130, and the 2 bends to each side of the cradle. I also put in 2 diagonals from the linkage mount / frame cross over much like you'd see on most steel frames.

I always set the Counter Shaft center of any 'hybrid' I make at the same height as the original engine (well, unless it's too bloody high as std, when you factor in the huge torque of a 500 2t) .Too many people end up placing that center too high, just to make 'ancillaries' easier to accommodate, but it's a great way to really, really stuff up your suspension and handling.

The Center of the CS and SA Pivot Center is dictated by the engine (but you can get fancy with offset case inserts for the SA pivot bolt to go through) , but I've found usually less than 5mm difference, as designers had long since learned that as small a distance as possible was the go.

I hope it works out for you - my mate that I did the KX500 / 16 SXF Hybrid for loves it, and it was an easy job to do. Being steel, with far smaller frame sections, makes things far simpler than an AF.

Lol... I appreciate your concern, I really do :-)
But, you missed something really important... but it will be made very clear over the next few days...
Things may not be as they appear to be...
I also appreciate your insight on alignments.
A lot of thought went into this, so stay tuned I think you'll be happy with my results..

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11/23/2017 6:42 AM

A bit more clean up and prep on the frame rails...

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One of the things I may not have mentioned is that these frame rails are really thin so great care was taken to not grind off any more material then was absolutely necessary...

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11/23/2017 6:57 AM

A bit of info:
Jason at JT Engine Works and I are working on this project together as we have the spare time.
Jason is a CR500 and KX500 specialist and works out of my shop.
He builds all types of dirt bike engines and chassis.

Here is a few engine builds he has done..

Bultaco Pursang 125
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1989 CR250
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KX500 bottom end with custom made 2 piece clutch cover
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Couple of KX500's
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Here is a couple of pics of his Championship winning CR500 build
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This thing is insane..
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Needless to say I am very happy to have him helping out on this build..

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11/23/2017 7:00 AM

PTshox wrote:

You're digging in! That's the only way to do it. It will all work out...kePhoto

keep an eye on the counter shaft sprocket location vs the swing arm pivoit bolt. You want the counter shaft
to be a little bit below the swing arm piviot bolt... )

Oh yeah... Thanks for the tips.

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