SuperMoto Junkie banner

KTM 500 2-stroke project

37K views 46 replies 26 participants last post by  ambiguous 
#1 · (Edited)
I just thought I would post some onfo on this KTM 500 2-stroke project since most of the parts have came from SMJ's. It was a good running '90 KTM when I started. It's been a learning experience, seems nothing fits without lots of major fabrication and fiddling, but it is coming along. It has a '06 SMR front end and brakes, '04SMC rear shock and SMC body work. The swing arm is the stock '90 KTM fabricated unit, looks way stronger than the cast ones on some of the newer bikes. The triple is a forged KTM with adjustable 14 to 20 offset.

I tried to post a pic but didn't work, but here's the link to all the pics: http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/

Any input is apreciated! Thanks, Dave
 
#3 · (Edited)
Hp

I have heard that they all are with in a few HP, but in stock form the KTM is followed by the KX then the CR. I think it has a lot to do with torque too. I do know this thing was a beast the little I rode it before the teardown, crazy fast acceleration. I read about 72 HP and 220 pds. Thats about 20 more than my SMC and aboot 100 pds. less, sounds like fun.

Also on a interesting note, some of the guys over at the KTM site PM'd me to say this couldn't be done, granted almost nothing has been a bolt on but that's what makes it a challenge. I've seen a bunch of Cr's and a few KX's but not a KTM yet. It's not pretty now but I plan to break it back down after I get the bugs worked out and attend to that this winter. I'm not happy with the see through air box area, was planning to put a big K&N there and an orange spring but leaning toward the airbox with stainless mesh coverd 1" holes. Still lots to figure out.

Dave
 
#9 ·
I have heard that they all are with in a few HP, but in stock form the KTM is followed by the KX then the CR. I think it has a lot to do with torque too. I do know this thing was a beast the little I rode it before the teardown, crazy fast acceleration. I read about 72 HP and 220 pds. Thats about 20 more than my SMC and aboot 100 pds. less, sounds like fun.

Also on a interesting note, some of the guys over at the KTM site PM'd me to say this couldn't be done, granted almost nothing has been a bolt on but that's what makes it a challenge. I've seen a bunch of Cr's and a few KX's but not a KTM yet. It's not pretty now but I plan to break it back down after I get the bugs worked out and attend to that this winter. I'm not happy with the see through air box area, was planning to put a big K&N there and an orange spring but leaning toward the airbox with stainless mesh coverd 1" holes. Still lots to figure out.

Dave
just build this...

http://www.advrider.com/forums/showthread.php?t=450118
 
#4 ·
nice one! I'm from the uk and have always loved two strokes, off road and on, it was a two stroke crosser that put me in a chair but i would love to be able to ride supermoto ;o) I'm a honda fan but great to see something different, they've always been fast ktm's as far back as i can remember and you've got it looking very up to date, good luck with that, hope you can post a link when it's done.

Jase
 
#8 ·
berg

I agree, there is more to HP than a power valve, or "power valves" kind of like a bike with a "power band". Anyway they are all plenty fast.

I do like the open area on the 'Berg. It's also hard to imagine what looks good too when a bike is up on a lift all the time, it's good to have options.


Dave
 
#11 ·
bike

Did a small test ride. All good, still a few small issues. Good brakes, awesome power, lifted the front wheel in 4th by mistake. So far so good. Next test will be at the Kart track so see how it handles and puts the power down, I think it will be a handfull.

http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/?action=view&current=DSCN3191.jpg

http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/?action=view&current=DSCN3192.jpg

My buddy Gary on a test ride, he got it going a little faster than he expected, note the grin, makes it all worth it!

http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/?action=view&current=DSCN3189.jpg

Thanks to all the guys that helped me with info and parts, Dave
 
#12 · (Edited)
Ktm

Well, in last few moths I've been busy with a move but still got some stuff done. Never made it to the track for a test as winter hit. Got all the fabrication done and sorted. All the new mounts welded and old ones removed. Figured out body work etc... Broke it all down and sent frame off to powder coaters. Only took about 2 hrs to have it down to the frame.

The frame is going to be a 60% satin black, charcoal grey mettalic engine, orange shock spring,and stainless steel braided hoses. Still debating in my mind to polish or make the swinger black, black would be differant? I plan to polish all the other all. bits.

The frame is still at powdercoat guy, so I have been detailing the engine a bit. Got the paint on and replaced all the cover bolts with Stainless hex heads. If anyone else does this, don't use the button heads, they may look nice but they strip way easy. Cheap stainless, like the button heads I used first and wasted 30 bucks, are actually really soft and they are shallow where the hex is so they are not good for engine suff, maybe OK for low torque apps.
I have a gold drive chain coming and some orange grips so as soon as frame is back it shouldn't be long. Here are some engine pics.


Thanks for the interst, Dave

http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/?action=view&current=DSCN3301.jpg

http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/?action=view&current=DSCN3328.jpg
 
#16 ·
Looks like a cool project! I've thought about buying a running 500, parting it out except for the motor, and putting it in a newer generation frame. I know you posted a general HP figure earlier, but have you done any dyno pulls with yours yet? I'd be interested. I'm probably going to run my 300 after I rebuild the topend, interested to see how much difference there is.

Gerry
 
#17 ·
ktm

Gerry,
No real #'s. The factory rating is like 72, and there are sveral guys that say thats about right stock, as everyone know HP #'s can vary from bike to bike and certainly from dyno to dyno. I think what ever it is it will be enough! 500's have some low end grunt which is good I think.

So with a pipe and a Mikuni carb instead of that bing it should be in the mid 70ish range.

I don't know why the pics don't show, heres a link to the whole batch of them. http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/



Thanks, Dave
 
#19 ·
theirs a ktm 500 2t? with 72hp stock! :bannana:
learn something new every day i guess

anyways i know the cr500 has 58-60hp stock, not sure on the torque numbers though. i dyno'd mine on a bad piston and got 48hp
the problem with the cr500 is that the factory kept the jetting real sloppy because the power hit was so ridiculous the factory riders told them to mellow out the power. so with the cr500 their more power if u get it ported properly.

i can't see ur pics, cause the school server blocks them. but im gonna check up on ur build when i get home. :thumbup:
 
#21 · (Edited)
Here ya go....I linked to it for ya.

Man...dude....that's a sweet bike.
I've always like the looks of the KTMs.
The black goes well w/the orange.

What's good about modding parts to fit a different bike???? It gives you more bragging wrights when people see it and ask questions.

Really clean build.
Awesome bike:thumbup:.

K&N filters are restrictive when compared to a foam filter. So whatever you do for the air box, get a Uni.

Before:

.
.




HOLY CRAP.......


.
.


.
 
#22 · (Edited)
ktm

Thanks for posting those, I can't seem to get them to post. The parts are done from the powder coater and I plan to pick them up tomarrow. I have a ton of polishing to do but should have it together real soon.

I'll post some pics of the parts and progress. My only last big decision is whether to polish the swingarm or make it black, I may spray bomb it and if it looks good have it powderd, or that paint would be easy to remove. I looked all over for a picture of one with a black swing arm with no luck. I'm also thinking about trimming the # portion of the side covers to give it a lighter look to the back of the bike. Maybe if I knew how to photo shop, lol


Thanks, Dave
 
#23 ·
that is one sick bike!!!


black swingarm would look good if you still haven't decided on black or polished.
 
#24 ·
If something looks out of place, then it shouldn't be done.
No other parts on the bike are polished.....the swing arm would look out of place if it was.
On the other hand, it would match the forks and graphics if it was powdered.
Might as well paint the sprockets and calipers while you're at it.

Go into the message box as if you were typing a reply, then down-size the page.
Open one of your pictures in a different page.
Left click on the "IMG code" to high-light the box.
Right click the img code to access the drop-down menu.
Left click onto copy.

Expand the page to access the message and right click in the message to access the menu.
Right click onto paste.
Waulah.....
You can the preview your post and make sure it took.

You can also link to an off-site avitar using a similar method.
Might have to use the direct link code for that (I can't remember).

Hope it works.
 
#25 ·
Ktm

Got the frame and other parts back from powder coater. Started putting back together. I'm satisfied with the satin black and charcoal engine. I went with polishing the swing arm, that took a LONG tiring time by hand. The pipe is polished nickel plate and a few bits are polished here and there so I figured I can always go with a black swing arm later, harder to go from powder coat to polished I figured.

Interesting it took a couple of hours to break down and it will be days going back. So far no major scratches. Lots more stainless bolts to buy, lots more to make look nice as I go. But it's starting to look like a bike again.

I'll try posting pics next time, kinda tired, long day. Here are links to what I got done today.

http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/?action=view&current=DSCN3383.jpg

http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/?action=view&current=DSCN3386.jpg

http://s719.photobucket.com/albums/ww197/DBR0051/KTM 500 Supermoto/?action=view&current=DSCN3385.jpg
 
#29 ·
ktm

Rob, I'm not sure yet. I bought the bike to convert and only ran it about 3 times. I kicked it with my right foot standing next to it. I know the guys that have them say you get use to it. I have a electric roller starter that I will take to the track!


Thanks, Dave
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top