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Thread: KTM 380 2T Supermoto Project

  1. #1
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    Exclamation KTM 380 2T Supermoto Project

    Hi, i'm in the process of stripping, cleaning and making my ktm 380 into a street legal supermoto, i've always wanted a big 2T and when this came up i had to have it,

    here some pics from the strip and rebuild

    The bike as i got it, was not in bad condition, owner had looked after the engine but frame and other bits need restoring
    Attached Images Attached Images
    • File Type: jpg 1.jpg (82.8 KB, 1361 views)
    • File Type: jpg 2.jpg (76.6 KB, 1338 views)
    • File Type: jpg 3.jpg (79.4 KB, 1335 views)
    • File Type: jpg 4.jpg (68.3 KB, 1333 views)
    • File Type: jpg 5.jpg (69.7 KB, 1344 views)
    Last edited by EZMOTO; 10-19-2012 at 12:30 AM.

  2. #2
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    Default Ktm 380 pt2

    Shock out and engine looks good but will be doing a full strip and leak test

    bore looks good and it has a wiseco single ring piston fitted
    Attached Images Attached Images
    • File Type: jpg 6.jpg (76.9 KB, 1333 views)
    • File Type: jpg 7.jpg (41.2 KB, 1325 views)
    Last edited by EZMOTO; 10-19-2012 at 12:31 AM.

  3. #3
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    Default Ktm 380 Rebuild

    Shock cleaned up and spring painted

    I have also finished the engine and its looking alot better than the last pic, piston looks very new and bore is excellent
    so glad thats all ok!
    Attached Images Attached Images
    • File Type: jpg 1.jpg (69.4 KB, 1321 views)
    • File Type: jpg 2.jpg (65.1 KB, 1325 views)
    Last edited by EZMOTO; 10-19-2012 at 12:32 AM.

  4. #4
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    Smile

    Now the hard part stripping all the powdercoat off the old frame

    i found a great spray that removes paint and powder coat easily
    it available from ebay UK its called avbiz paint stripper

    and its awesome here's what the frame looked like after 15 mins of being spayed
    the powdercoat just falls off!

    i made a video short video on youtube about it as well to help others
    https://www.youtube.com/watch?v=iqXXsCQSyz0
    Attached Images Attached Images
    Last edited by EZMOTO; 10-19-2012 at 12:40 AM.

  5. #5
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    Pictures no worky, could be my phone. Cant wait to check it out later.
    2007 Aprilia SXV 550 - First full size SM! Whoot!
    2008 GSXR 600 - Yes, Yes.
    2008 Ninja 250r - 1st bike. - Sold
    2007 RMZ450 - Sold
    2006 SSR 140 - Mini Tard

  6. #6
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    Default

    congratz to this project! keep going!

  7. #7
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    How did you clean the engine to make the aluminum so bright or is it painted?
    '06 DRZ400SM "Tubeless Conversion","Free power Mod"
    "09 WR450F DS right now, heading to SM
    '01 YZ250
    "If you can't be a good example, then you'll just have to be a horrible warning."

  8. #8
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    Hi i just used silver heat proof spray on the barrell and head

  9. #9
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    *update i'm in the process of polishing the swingarm while i wait for paint to arrive to paint the frame

  10. #10
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    I hate you for having a 380... i want one of these motors so bad.
    2003 KTM 450 EXC Supermoto
    2008 KTM 250 SX Supermoto (sold)
    2003 MZ Baghira 660 Street Moto (sold)
    1993 KTM 300 MXC Suoermoto (sold)
    1993 Suzuki RM125 Supermoto (sold)

  11. #11
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    Very nice!
    How do you painted the engine? It's spray paint or powder coating?
    KTM 380 SMR
    DR-Z400SM 3x3 , FCR39MX , JD , MRD/SSW , MAGURA/BREMBO4P/BRAKING320MM, IMS 2.6 SOLD

  12. #12
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    Quote Originally Posted by szymon View Post
    Very nice!
    How do you painted the engine? It's spray paint or powder coating?
    i use Hammerite Satin rattle can, on the cases, ive used this before its petrol proof and hard wearing

  13. #13
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    Quote Originally Posted by Meeners View Post
    I hate you for having a 380... i want one of these motors so bad.
    i know what you mean i had to sell the mrs and the kids to buy this one

  14. #14
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    Red face

    Finally got the frame painted in Satin Black and i'm starting to polish the triple clamps and swingarm, cant wait to start getting this bike rebuilt
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  15. #15
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    anyone know how to restore the colour on a plastic tank mine has few light scratches and is kinda dull?

  16. #16
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    What i have seen guys do when they restore older bikes is they wet sand it and obviously just start with a rough grit and work to a finer grit to smooth it out. After that they apply wax or a polishing compound to really shine it up.

    Thats a nice arsenal of motards you got there that CR is especially sweet, and it looks like this bike is coming along nicely keep up the good work!

  17. #17
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    thanks i'll look into that, i also see some guys using a heat gun

  18. #18
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    Swinger after half day polishing is looking good, still a good way to go yet though
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  19. #19
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    Cool project, I love large capacity 2 stroke supermotos.

  20. #20
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    looks awesome so far.. did you paint he cases black and silver on the side or buy new ones..it made the engine look so much more detailed..keep up the good work

  21. #21
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    Hi, i painted the cases black but put grease on the KTM RACING part which i previously polished prior to painting, so after paint dried it easily wiped off

  22. #22
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    got the engine and swinger mounted, and its starting to take shape now, still unsure on panel colours and decals yet, i want to go for the later 300 back end anyone know if i have to have subframe as well or can i just mod 300 rear mudgaurd on the stock 380 subframe ?
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  23. #23
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    Looking great! That powder coat removal spray is amazing! keep it the good work

  24. #24
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    This is going to be dope.
    Pew Pew. Lazerz.

  25. #25
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    Default Sweet!

    Lookin Good! Keep the pics coming
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  26. #26
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    Managed to get the clamps polished today, also checked out the reed block it turns out i have dual stage reeds fitted anyone know if these are any good, on my old 2 stroke racer we used very thin carbon fibre, these reeds i have in at the moment are fibre glass and seem quite stiff, prob better for top end and less flutter?
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  27. #27
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    How do you polish your stuff? I can see my soul in your parts. Con't the good work.
    2007 Aprilia SXV 550 - First full size SM! Whoot!
    2008 GSXR 600 - Yes, Yes.
    2008 Ninja 250r - 1st bike. - Sold
    2007 RMZ450 - Sold
    2006 SSR 140 - Mini Tard

  28. #28
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    Default polishing

    I just use a simple 1/2 hp bench grinder with a fine polishing mop attached.
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  29. #29
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    nice!!!

  30. #30
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    just a quick polish up on the gnarly pipe and silencer
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  31. #31
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    Managed to get alot done today, including vinyl wrap the front forks as i thought this would be the easier and better than painting them, came out spot on! bars and controls done, its starting to look like a bike now, carb cleaned and fitted, i'm running a 175 main and 42 pilot at sea level anyone have any info on jetting for the 380 as plug did look a bit lean when i pulled it before the rebuild.
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  32. #32
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    Hi, just wondering, what polish do you use ?

    Thanks
    Jake
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  33. #33
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    its a compund you want you use black for getting the rough stuff off then green for fine polishing

    heres an ebay link to similiar stuff

    http://www.ebay.co.uk/itm/Fine-Grade...item4607c9a0f3

  34. #34
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    Quote Originally Posted by EZMOTO View Post
    got the engine and swinger mounted, and its starting to take shape now, still unsure on panel colours and decals yet, i want to go for the later 300 back end anyone know if i have to have subframe as well or can i just mod 300 rear mudgaurd on the stock 380 subframe ?
    I know with the 300's you need the 04+ airbox, subframe, mudflap, and rear fender. idk if youve had a ktm 2 stroke before but make sure you do some runs with a new spark plug to make sure you have a good coffee color on the plug. They can be a bitch if not jetted right. For like 600 bucks you can pick up SMR forks and rear shock. I would do that that way you can bolt on all the later SM goodies with the 26mm axel.
    04 KTM 450 SMS
    08 KTM 690 SMC
    12 Triumph Street Triple R
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  35. #35
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    Saaaweet!!!

  36. #36
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    Quote Originally Posted by B_palmer22 View Post
    I know with the 300's you need the 04+ airbox, subframe, mudflap, and rear fender. idk if youve had a ktm 2 stroke before but make sure you do some runs with a new spark plug to make sure you have a good coffee color on the plug. They can be a bitch if not jetted right. For like 600 bucks you can pick up SMR forks and rear shock. I would do that that way you can bolt on all the later SM goodies with the 26mm axel.

    If you change airbox than you need to change seat.
    KTM 380 SMR
    DR-Z400SM 3x3 , FCR39MX , JD , MRD/SSW , MAGURA/BREMBO4P/BRAKING320MM, IMS 2.6 SOLD

  37. #37
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    cheers i had a look on ebay but there does not seem to be many parts for the ktm, have you got a list of what bikes are suitable and what years for this transplant? i.e can i use 125 or 250?

  38. #38
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    I have subframe from 125. 250 will fit also.
    You most looking subframe with two handles for muffler. Because some bikes have only one muffler handle.
    KTM 380 SMR
    DR-Z400SM 3x3 , FCR39MX , JD , MRD/SSW , MAGURA/BREMBO4P/BRAKING320MM, IMS 2.6 SOLD

  39. #39
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    Very awesome project! Congratulations on choosing the correct engine configuration.

    Great finish on the polished parts. I'm just wondering about your triple clamps - did you just use a grinder/sander to smooth out the casting marks? Any tips & tricks there? I'm looking to get mine all smooth ready for paint.

    Looking forward to seeing how this progresses, may give me some ideas for my 380!

  40. #40
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    Hi, i used a small sanding wheel in my dremmel multi tool, to smooth the side castings on the clamps, then polished them up until it was all smooth. but you really need a good sisal mop for polishing out marks in the alloy

  41. #41
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    been looking for a good set of wheels cheap and then these popped up, so had to have them, there going to look sweet on the 380, bargain as well complete with braking wavy front and rear disks!
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  42. #42
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    anyone know where to get a 320mm brake adapter for my forks cheapish?

  43. #43
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    Wow, Very nice.

    You better google zoopseal

    That polished alum will fade quick. Ask me how I know.

    Taking the casting ridges of the triples is awesome too. Good work.

  44. #44
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    Quote Originally Posted by pazzoduc View Post
    Wow, Very nice.

    You better google zoopseal

    That polished alum will fade quick. Ask me how I know.

    Taking the casting ridges of the triples is awesome too. Good work.


    cheers, I have found if you polish up something good and get a deep shine, then fading takes ages, also matters where you keep your bike mines kept in a warmish garage so that helps

  45. #45
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    rad pipes and electrics now fitted, also just restored the stock pegs as well, saved me a few quid there

    im waiting for my 2005 subframe and airbox which i'll be fitting for a sweeter looking back end
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  47. #47
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    Man that thing is looking factory fresh!
    2007 Aprilia SXV 550 - First full size SM! Whoot!
    2008 GSXR 600 - Yes, Yes.
    2008 Ninja 250r - 1st bike. - Sold
    2007 RMZ450 - Sold
    2006 SSR 140 - Mini Tard

  48. #48
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    Quote Originally Posted by Macco568 View Post
    Man that thing is looking factory fresh!
    thanks bud, just polished up the rear brake as well !




    i just love polishing shit!

  49. #49
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  50. #50
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    Haha. Nice, i just bought a kit like the one yo u posted, gonna give it a shot. Just need something with enough RPM on it you sandthis stuff first?
    2007 Aprilia SXV 550 - First full size SM! Whoot!
    2008 GSXR 600 - Yes, Yes.
    2008 Ninja 250r - 1st bike. - Sold
    2007 RMZ450 - Sold
    2006 SSR 140 - Mini Tard

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