cr500 KTM conversion

Building Tips, Suspension Set Ups, Conversion Parts .... Build to your Heart's Content!
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craigf40
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Joined: January 19th, 2010, 12:41 pm
Location: johannesburg south africa

Re: ktm conversion

Post by craigf40 »

blownbillybob wrote:hey !!! looks good!!!

been working on my ktm conversion and building a new engine for it also ,can't wait to ge it going ill have to snag the wifes camera and try and get some pics up, just been hell busy with work!!
Looking good i cant wait to see it when its finished .... I think you should consider beefing
your head stay bracket up making it more of a triangular shape the cr500
vibrates a fair amount especially if your head stay is not solid
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jar944
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Joined: August 12th, 2009, 7:15 am

Re: ktm conversion

Post by jar944 »

craigf40 wrote:Looking good i cant wait to see it when its finished .... I think you should consider beefing
your head stay bracket up making it more of a triangular shape the cr500
vibrates a fair amount especially if your head stay is not solid
I may change them, though the original factory stay is that way for the flex characteristics.
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blownbillybob
Posts: 391
Joined: March 13th, 2008, 9:50 pm
Location: FRISCO

Ktm conversion

Post by blownbillybob »

I like those bushings !! I think I'm going to stick with the spacers tho!! I will be switching out engines so I don't want to get stuck with one set of cases????

I went with a triangle headstay pretty HD tho maybe overkill!! 3/16 alum. Plate

The guy I got the frame from had already cut the mounts out and there was not much left of them?? So I cut out some CR mounts and used some 7/16 bolts!
00'cr500 trailclimber
93'cr500 beater
92'cr500 hillclimber
08,KTM SR500r hillclimber (conv)
89'cr 500 bent frame
04'crf230(wifeys)
02' cr125(sons)
02,pro jr 50 open exh. hill climber(sons)
02'sx65(sons)
03'xr50(sons)
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jar944
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Re: Ktm conversion

Post by jar944 »

blownbillybob wrote:I like those bushings !! I think I'm going to stick with the spacers tho!! I will be switching out engines so I don't want to get stuck with one set of cases????

I went with a triangle headstay pretty HD tho maybe overkill!! 3/16 alum. Plate

The guy I got the frame from had already cut the mounts out and there was not much left of them?? So I cut out some CR mounts and used some 7/16 bolts!
where are the pics? :D
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Roostius_Maximus
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Post by Roostius_Maximus »

watch out for that carb bowl to not be on too much of an angle, i'm guessing its just the way the picture was taken
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jar944
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Post by jar944 »

It should move a bit faster now that I have most of the parts to finish
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jar944
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Post by jar944 »

So I finally got around to putting the bottom end together and noticed the shift drum was cracked. So now I'm waiting on more parts.

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AlisoBob
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Post by AlisoBob »

Good eye!!!!
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jar944
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Post by jar944 »

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

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2strokeforever
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Location: Vernon B.C Canada

Post by 2strokeforever »

cant wait to hear how it turns out, i may be doing one eventualy

i like how youre keeping the oem ktm headstay
the 450 will have less power and will be harder to start, and will be heavier, but to make up for it it will require more maintenance.
4stroke=dead fish
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hoofarted
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Location: Rancho Cucamonga, CA

Post by hoofarted »

2strokeforever wrote:cant wait to hear how it turns out, i may be doing one eventualy

i like how youre keeping the oem ktm headstay
...and pipe and silencer :shock:

What are you doing with the missing coolant fitting?
The CR500 is an acquired taste. If you don't like it, acquire some taste...

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jar944
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Post by jar944 »

hoofarted wrote:
2strokeforever wrote:cant wait to hear how it turns out, i may be doing one eventualy

i like how youre keeping the oem ktm headstay
...and pipe and silencer :shock:

What are you doing with the missing coolant fitting?
The pipe is the stock 500, the silencer is a mix of the KTM silencer body, a new 1.25" core (matches the the dia of the 500 core) and the stock 500 silencer tubing cut, sectioned and turned from the can to the pipe.

The other outlet on the head will have a plug threaded in.
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blownbillybob
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Joined: March 13th, 2008, 9:50 pm
Location: FRISCO

Post by blownbillybob »

jar944 wrote:
Imageimg]
I'm at this same stage right now to!!!

I was able to squeeze the cr coil and cdi box under the tank !!!!!

:cool:
00'cr500 trailclimber
93'cr500 beater
92'cr500 hillclimber
08,KTM SR500r hillclimber (conv)
89'cr 500 bent frame
04'crf230(wifeys)
02' cr125(sons)
02,pro jr 50 open exh. hill climber(sons)
02'sx65(sons)
03'xr50(sons)
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jar944
Posts: 57
Joined: August 12th, 2009, 7:15 am

Post by jar944 »

blownbillybob wrote:
jar944 wrote:
Imageimg]
I'm at this same stage right now to!!!

I was able to squeeze the cr coil and cdi box under the tank !!!!!

:cool:
Nice.. you need to post some pics.

BTW I'm planing on shipping the parts out tomorrow.
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jar944
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Post by jar944 »

I should have it wrapped up this weekend. I still have a bunch of little things to do before it's done.

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jar944
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Post by jar944 »

Just some pics of the cdi placement, coolant block off for the head, and carb fitment.

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hoofarted
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Post by hoofarted »

The coolant goes thru the frame? At least thats what it looks like from the pic..
The CR500 is an acquired taste. If you don't like it, acquire some taste...

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jar944
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Post by jar944 »

hoofarted wrote:The coolant goes thru the frame? At least thats what it looks like from the pic..
Sort of.

All 08+ KTM's have through the frame coolant pluming. The top of the rads have a outlet that fits directly into a "T" fitting inside the frame.
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jar944
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Post by jar944 »

I wasnt happy with the exhaust mounting and routing so i decided to fix it

tweaked silencer
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way more clearance
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rear pipe mount
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The pipe is cut back to the cone and the flange and rear mount welded
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exhaust complete
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compelted head stays
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It's Done. the only custom parts are the frame mounts, head stay and the exhaust and even that isn't much work

also with this conversion I can pull the carb with everything in place (unlike the AF's)


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asteroid500
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Location: Australia Melbourne

Post by asteroid500 »

ride report pls, looks mean as cats piss .... great job
"not speeding officer".....qualifying

CR250 97
CR500 AF 99 (in progress)
CR500 AF CR G-4
CR500 1985 true legend
RGV250 96 X2
GSXR600 07 TRACK BIKE
VH Commadore cup car (race)
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jar944
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Joined: August 12th, 2009, 7:15 am

Post by jar944 »

asteroid500 wrote:ride report pls, looks mean as cats piss .... great job
Just rode it around the yard so far, I'll get the ride report after next weekend.
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homenf
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Joined: October 11th, 2009, 10:35 am
Location: Sparks, NV

Post by homenf »

I want one!
94 CR125
06 CR500AF

"I'd give you my two cents on this hope and change thing, but I can't afford to anymore."
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jar944
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Joined: August 12th, 2009, 7:15 am

Post by jar944 »

vid from sat riding the 500ktm
http://www.youtube.com/watch?v=ks4VM4OaWes

ended up having some detonation issues
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blownbillybob
Posts: 391
Joined: March 13th, 2008, 9:50 pm
Location: FRISCO

Post by blownbillybob »

Looks like you had some fun!!!! And it's running good!!

Where's it detonating at a real low rpm lugging it around or on the hillclimbs???

It could be allittle lean?? If not ,cut down the squinch pad to 15mm wide

How's the temp running , are u using ktm rad cap or cr???
00'cr500 trailclimber
93'cr500 beater
92'cr500 hillclimber
08,KTM SR500r hillclimber (conv)
89'cr 500 bent frame
04'crf230(wifeys)
02' cr125(sons)
02,pro jr 50 open exh. hill climber(sons)
02'sx65(sons)
03'xr50(sons)
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jar944
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Joined: August 12th, 2009, 7:15 am

Post by jar944 »

blownbillybob wrote:Looks like you had some fun!!!! And it's running good!!

Where's it detonating at a real low rpm lugging it around or on the hillclimbs???

It could be allittle lean?? If not ,cut down the squinch pad to 15mm wide

How's the temp running , are u using ktm rad cap or cr???
On the climbs when it's hot, but not consistently.

You can hear it here (4-6 second mark) then it goes into a lean surge at the top. http://www.youtube.com/watch?v=kj2_k7JLc0g

The jetting does not feel lean though 50/dgl-3rd/175. It's not running hot it never boiled, ktm 1.8 cap
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