KTM SX 150 from 2010 to 2017 Plastic Retrofit

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12/9/2018 11:55 AM
Edited Date/Time: 12/9/2018 11:57 AM

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.
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12/13/2018 1:32 AM
Edited Date/Time: 12/13/2018 1:34 AM

This is awsome! Anyone done this upgrade to a 2011 to 15 model? Anyone know what's involved?

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12/13/2018 2:56 AM

Cliffy615 wrote:

This is awsome! Anyone done this upgrade to a 2011 to 15 model? Anyone know what's involved?

I had 2013 model and I can say it's more like 2016 model frame, so it will be less complicated to convert. Gas tank fit better due to frame similarity, only problem is subframe mounts. I seen on this forum someone has retrofited 16 on 13 - try searching on forum.

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12/31/2018 9:20 AM
Edited Date/Time: 12/31/2018 9:22 AM

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.

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12/31/2018 9:24 AM

Final result, still waiting for battery tray and air filter.Photo
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12/31/2018 9:31 AM
Edited Date/Time: 12/31/2018 9:39 AM

WP Closed chamber (bladder type) forks mod:
Some may know that WP CC forks has really good bottoming performance but it has mid stroke harshness, so to fix that I made custom spring seat perches - what it does lets you to soften forks without loss of bottoming performance by allowing less oil through.

Made nitrogen refill needle from wheel valve, pneumatic tubing and medical needle smile
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Stock perch
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Some CAD work Photo
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Made holes small enough so I could adjust performance of bottoming by drilling em out Photo

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12/31/2018 1:47 PM

nice work... explain the carb/airboot connection some more.

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vomiting equals disqualification.

12/31/2018 2:26 PM

BR8ES wrote:

nice work... explain the carb/airboot connection some more.

I made adapter to extend mounting because 2016 carb or air boot position changed Photo
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a lil bit of heat and massaging air box plastic worked nicely.

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12/31/2018 2:39 PM

BR8ES wrote:

nice work... explain the carb/airboot connection some more.

Balzabubinas wrote:

I made adapter to extend mounting because 2016 carb or air boot position changed Photo
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a lil bit of heat and massaging air box plastic worked nicely.

I saw that, interesting. Press fit?

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vomiting equals disqualification.

12/31/2018 2:42 PM

BR8ES wrote:

nice work... explain the carb/airboot connection some more.

Balzabubinas wrote:

I made adapter to extend mounting because 2016 carb or air boot position changed Photo
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a lil bit of heat and massaging air box plastic worked nicely.

BR8ES wrote:

I saw that, interesting. Press fit?

Heat press fit with a little bit of sealant - wont go anywhere

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12/31/2018 3:21 PM

Balzabubinas wrote:

I made adapter to extend mounting because 2016 carb or air boot position changed Photo
Photo
a lil bit of heat and massaging air box plastic worked nicely.

BR8ES wrote:

I saw that, interesting. Press fit?

Balzabubinas wrote:

Heat press fit with a little bit of sealant - wont go anywhere

Nice work and ingenuity.

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vomiting equals disqualification.

1/2/2019 11:09 AM

Great work bro!. Really like to see stuff like this. Well done.

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2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.

imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.

1/2/2019 11:26 AM

#76 wrote:

Great work bro!. Really like to see stuff like this. Well done.

Thank you, received final parts, result looking good smile cant wait to rip this thing, damn winter...Photo
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1/3/2019 12:40 AM

It sure does look good. Winter.....man dont start me off!...I hate it here in the U.K. its cold, damp, wet and windy!.

I look at how the guys in parts of the U.S. can ride all year round and its making me really think of selling up and heading somewhere better to be able to enjoy what i love doing for a few more years!.

You said that you saw a thread on a 16 - 13 plastics swap?, i have searched and can not find that one anywhere?, can you remember the O.P.?.

I have a 5hr old 2014 KTM 250 sx and might just have a go. smile

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2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.

imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.

1/3/2019 1:40 AM

#76 wrote:

It sure does look good. Winter.....man dont start me off!...I hate it here in the U.K. its cold, damp, wet and windy!.

I look at how the guys in parts of the U.S. can ride all year round and its making me really think of selling up and heading somewhere better to be able to enjoy what i love doing for a few more years!.

You said that you saw a thread on a 16 - 13 plastics swap?, i have searched and can not find that one anywhere?, can you remember the O.P.?.

I have a 5hr old 2014 KTM 250 sx and might just have a go. smile

Doing what you love is the key to happiness!
https://m.vitalmx.com/forums/Bike-Builds,46/KTM-PLASTICS-CONVERSION-2017,1329594
There's no info about retrofit, only one picture. But I can say that 2013-2015 would require less work than my bike, just because frame is more familiar to 2016 model.
If I were you, I would find 2016 parts to borrow - just mock it up then you will know how much work it takes, that's how I got into it.

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1/3/2019 2:02 AM

#76 wrote:

It sure does look good. Winter.....man dont start me off!...I hate it here in the U.K. its cold, damp, wet and windy!.

I look at how the guys in parts of the U.S. can ride all year round and its making me really think of selling up and heading somewhere better to be able to enjoy what i love doing for a few more years!.

You said that you saw a thread on a 16 - 13 plastics swap?, i have searched and can not find that one anywhere?, can you remember the O.P.?.

I have a 5hr old 2014 KTM 250 sx and might just have a go. smile

Balzabubinas wrote:

Doing what you love is the key to happiness!
https://m.vitalmx.com/forums/Bike-Builds,46/KTM-PLASTICS-CONVERSION-2017,1329594
There's no info about retrofit, only one picture. But I can say that 2013-2015 would require less work than my bike, just because frame is more familiar to 2016 model.
If I were you, I would find 2016 parts to borrow - just mock it up then you will know how much work it takes, that's how I got into it.

Great work with the bike! I have a 2016 exc that I´m thinking of retrofitting 17-18 plasti, but it is hard to find any builds. In that link you will find two different pictures of retrofitted bikes, first is made by a company in France, Elite moto 15 : https://www.facebook.com/elitemoto15/ that is a complete rebuild, but not much more info then that picture, the second one, the blue bike looks to have the plastic bolted on top of the old plastic/airbox.

When you are done you can head over to Sweden and ride some deep snow with studded tires instead of the mud in UKsmile

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1/3/2019 9:27 AM

Enjoyed reading this build, great attention to detail and the end result looks spot on

I'm in the UK and have the MX blues right now sad

Just keep looking at my RM125 in the garage and dreaming of giving it a good thrashing round Canada heights

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1/5/2019 8:20 AM

Few more pics Photo
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1/6/2019 1:41 PM
Edited Date/Time: 1/6/2019 1:42 PM

Great build! Very cool and I am thinking of doing something similar on my 250 exc 2011.

What did you have to do on the gas tank and could you share some pictures of it?

The airbox you used from a 125/150/250sx? Are all using same parts?

Cheers from Sweden!

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1/7/2019 11:44 AM

MarcusMotoDesign wrote:

Great build! Very cool and I am thinking of doing something similar on my 250 exc 2011.

What did you have to do on the gas tank and could you share some pictures of it?

The airbox you used from a 125/150/250sx? Are all using same parts?

Cheers from Sweden!

Hello,
Gas tank needed heating to be able to form it inside tunnel area, dont have pictures of process but what you need is heat gun, empty tank and patience. I think 2011 year has different frame than mine so it should require less modifications. Heat up tunnel area, with plastics on put on frame and press it until radiator bolts line up. Air box from 125, but I think 250 would work if carb mounting diameter is the same, cheers.

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1/7/2019 2:15 PM

Thanks a lot! I think I will have a go at it! ?

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1/7/2019 4:24 PM

This is awesome, beautiful work. Always wondered if this could be done. I've seen someone take an 04 or so era 200SX up to 2015 (from memory) plastic, you've done another leap up to the later shape. Maybe the 2006 KTM 300 in my garage could get an update?

PS: If you want to ride year round, move down to Australia cool

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The best riding is in winter, when its not too hot!



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1/14/2019 3:00 PM

mitch199 wrote:

This is awesome, beautiful work. Always wondered if this could be done. I've seen someone take an 04 or so era 200SX up to 2015 (from memory) plastic, you've done another leap up to the later shape. Maybe the 2006 KTM 300 in my garage could get an update?

PS: If you want to ride year round, move down to Australia cool

Photo

The best riding is in winter, when its not too hot!



Mitch, oh man.... I can only imagine what that must be like....I am so fed up of England, in general!, let alone the shitty weather, and to look see that pic you posted I just hope you guys know how lucky you really are to be able to enjoy something you love all year round. Good on you guys!.

O.P. Have you had a blast on the bike yet?.

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2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.

imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.

2/11/2019 7:44 AM
Edited Date/Time: 2/11/2019 7:46 AM


Freshly rebuilt wheels - new bearings, seals, spacers, powdercoated rims, polished hubs all on fresh MX3S rubbers
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2/11/2019 2:12 PM

Looking good!. Let us know how the Powdercoating holds up on the rims. wink

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2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.

imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.

2/12/2019 1:54 AM

#76 wrote:

Looking good!. Let us know how the Powdercoating holds up on the rims. wink

Had 3 bikes with powdercoated rims - it holds great, even when you go crazy with tire spoon while mounting tire it holds good.

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3/8/2019 10:47 AM
Edited Date/Time: 3/8/2019 10:52 AM

Nice work! I am attempting '13 to '17 now. If anyone is wondering 2017 tank does not drop onto 2013.

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3/8/2019 11:01 AM

jbstaten wrote:

Nice work! I am attempting '13 to '17 now. If anyone is wondering 2017 tank does not drop onto 2013.

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Good info, the 2013 frame is same as mine 2016 EXC-F if I´m not mistaken? I was hoping that the gastank would fit nicely and my plan therafter would be carbon for the rear fender and sideplates.

I have noticed that the new 2019 model have a longer subframe and flatter sideplates/rearfender, but the gastank has the fuelpump on the side. Plastics looks to have a better fit on the old frame but I might be wrong since the tank looks alot different. Anyone have had a closer look?

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3/8/2019 11:31 AM

jbstaten wrote:

Nice work! I am attempting '13 to '17 now. If anyone is wondering 2017 tank does not drop onto 2013.

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Welcome to Vital!.

That's some good info right there, thanks. Maybe start your own thread as it looks like there will be some good info for others.

Keep us updated as I have a 2014 I am thinking of having a go at.

...OP, have you had a blast on her yet?...

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2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.

imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.

3/8/2019 12:40 PM

jbstaten wrote:

Nice work! I am attempting '13 to '17 now. If anyone is wondering 2017 tank does not drop onto 2013.

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It looks like you need to relocate top tank pin - lower it down and it should fit. Best way to approach conversion is to have subframe, plastics, tank and seats to have everything lined up before making modifications

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