KTMonda CR500 450sxf conversion

Discussion in '2 smokers' started by jar944, Jan 20, 2012.

  1. jar944

    jar944 Been here awhile

    Joined:
    Aug 2, 2010
    Oddometer:
    752
    Location:
    Chantilly VA
    I've already done 2 ktm to ktm 4t hybrids: http://www.advrider.com/forums/showthread.php?t=662808


    I got a good deal on a Craigs list CR5 and already had a 08 ktm roller in the garage. From the 2 other ktm hybrid builds I've seen it should almost be a bolt together build. The Honda parts will worked over as well, I just want to get the chassis done first.

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    pivot spacers and getting the sprocket into the correct horizontal alignment.
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    The right rad outlet points in the wrong direction (for a 450sxf radiator)
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    The right outlet is perfect
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    The shock spring to pipe clearance may need some tweaking
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    Old mounts cut out and cleaned up
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    Re-positioned for the 500 engine and welded back in
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    #1
  2. anotherguy

    anotherguy Long timer

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    Hmmm..................very interesting.
    #2
  3. yzmaico

    yzmaico Slacker

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    WOW!! I think the CR500 bike will be fantastic, I rode a Service Honda 500 awhile back and I couldn't believe the difference with the motor mounted in a new CR frame.
    #3
  4. jar944

    jar944 Been here awhile

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    The 2t (07 125sx) radiators work with no issues

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    I'm just waiting on the carb boot and silencer to show up and I can finish the remaining fabrication

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    #4
  5. jar944

    jar944 Been here awhile

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    Slightly cleaner engine, allough in the process of cleanign i noticed the crank was semi submerged in oil..
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    crack
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    I have no idea what this is
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    monkeys should not have tools, the stator side seal is bottomed out as well
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    cleaner
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    some baking 30min @ 300
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    easy as Pie
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    On the plus side the cylinder is still on the stock bore, and it looks like the case issue is just some casting flaws. now to see how a ultrasonic cleaner does
    #5
  6. jar944

    jar944 Been here awhile

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    cases directly out of the ultrasonic cleaner

    before
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    after
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    The 2t carb boot while not perfect (the angle of the reed boot is not the same as the filter boot) it will work out.

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    The head, cylinder and cases cleaned up

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    The final case bushings machined and the head stay finished(cut and welded 250sxf stays)
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    It should move a bit faster now that I have most all the parts to finish
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    #6
  7. anonny

    anonny What could go wrong?

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    Very cool, thanks for posting, I just gotta ask though.... what happened to the stock motor?

    edit, never mind I just spent quite a bit of time reading your links. This build would make an awesome timber sled bike.
    #7
  8. jar944

    jar944 Been here awhile

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    ha, yeah this it the 3rd roller I pieced together from multiple sources. If you shop around you can do it for not much money.
    #8
  9. dorkpunch

    dorkpunch Oops...

    Joined:
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    Suhweet. Friend of mine had a CR500 he did up as a trail bike, it was surprisingly useable in the woods and would climb any hill ever.

    As for the timbersled- I STILL don't understand why nobodies done that yet (well, i guess I've seen some versions on a CR500 but no report as to how they perform). If I ever get my 495 pieced together and if I can ever afford a timbersled, I'll let you know how they work. Don't hold your breath though, that's a lot of ifs. :lol3

    Can't wait to see how it turns out!
    #9
  10. Rocket_Rookie

    Rocket_Rookie Learning the ropes!

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    Location:
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    What a great build up!

    Very neatly done, thank you for sharing with us! Please post an update of the work you have done thus far!
    Since I discovered the mechanical simplicity of two strokes, I am intrigued by the Honda CR range!
    Can't wait for your next post

    Regards,

    Rocket_Rookie
    #10
  11. AWM

    AWM Beard Bros Racing

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    :ear


    BBBbbbrrraaaappppp!!!
    #11
  12. jar944

    jar944 Been here awhile

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    I managed to get the cases back together, The silencer changed to a 1.25" core, and a new outlet in the head.

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    #12
  13. Rocket_Rookie

    Rocket_Rookie Learning the ropes!

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    That engine is really shiny..... Wow.
    #13
  14. jar944

    jar944 Been here awhile

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    especially when you compare it to how it looked a few months ago...
    #14
  15. Sniper X

    Sniper X De Oppresso Liber

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    That is one of the best motors every built. I will never forget my first ride on the CR500R.....80mph wheelies as easily as most bike wheelie at 30mph. And the thing never seemed to run out of arm stretching power.
    #15
  16. jar944

    jar944 Been here awhile

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    I should have it wrapped up this weekend, still have a bunch of little things to do.
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    #16
  17. anonny

    anonny What could go wrong?

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    How does the KTM can work on the expansion chamber?
    #17
  18. jar944

    jar944 Been here awhile

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    great once you increase the all the tubing and baffle from 25mm to 32mm.
    #18
  19. ssregal39

    ssregal39 Been here awhile

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    that is a sweet project. can't wait for a ride report.:clap
    #19
  20. Chris618

    Chris618 Been here awhile

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    Awesome build! I would love to see that thing go.
    #20