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Thread: KTM 500 2-stroke project

  1. #1
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    Default KTM 500 2-stroke project

    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/w...0%20Supermoto/

    Any input is apreciated! Thanks, Dave
    Last edited by DBR0051; 10-01-2009 at 11:50 PM.

  2. #2
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    awesome idea...I would be so curious to compare a dyno of a kx cr and ktm 500....i have to say the geometry / subframe looks dated...but who gives a fuck! its a goddamned 500 2 smoke! Cant wait to see it all complete!
    SM USA #322.
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  3. #3
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    Default 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
    Last edited by DBR0051; 10-01-2009 at 11:53 PM.

  4. #4
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    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

  5. #5
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    That bike doesnt have power valves, nore does the CR, so I say the KX would have most Power, because it has Power Valves.
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  7. #7
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    Quote Originally Posted by hey Johnny Park View Post
    That bike doesnt have power valves, nore does the CR, so I say the KX would have most Power, because it has Power Valves.
    it doesn't work that way mate.......

    DBR0051, that is looking very cool. I think the open area where you'd expect to see an airbox is great. Looks like a Berg!
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  8. #8
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    Default 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

  9. #9
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    Quote Originally Posted by DBR0051 View Post
    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...

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  10. #10
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    Default update

    I posted some new pics on the photobucket. It's REAL close to a test ride. The front brake fought us a bit, like everything else.

    I will post up the on the ground pics soon too.


    Dave

  11. #11
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    Default 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/w...t=DSCN3191.jpg

    http://s719.photobucket.com/albums/w...t=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/w...t=DSCN3189.jpg

    Thanks to all the guys that helped me with info and parts, Dave

  12. #12
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    Default 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/w...t=DSCN3301.jpg

    http://s719.photobucket.com/albums/w...t=DSCN3328.jpg
    Last edited by DBR0051; 02-03-2010 at 01:09 AM.

  13. #13
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    cant see pics and want to bad

  14. #14
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    Keep the updates and pics coming, big bore stroker = pornography for me lol
    Again, all the best from the UK for as pain free build as poss

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    your riding without a helmet!.....you should know better. haha
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  16. #16
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    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
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  17. #17
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    Default 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/w...0%20Supermoto/



    Thanks, Dave

  18. #18
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    looks so sweet 90s retro motards are where its at for me im building a ktm 360 96 mod
    black swing arm for sure
    whats the bore and stroke on the 500? Hmm these a wreaker on ebay in aus at the moe.

  19. #19
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    theirs a ktm 500 2t? with 72hp stock!
    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.
    1993 Cr500r
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  20. #20
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    Subscribed!
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  21. #21
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    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.

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    HOLY CRAP.......


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    .
    Last edited by PingKing; 02-07-2010 at 07:47 PM.
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  22. #22
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    Default 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
    Last edited by DBR0051; 02-08-2010 at 12:41 AM.

  23. #23
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    that is one sick bike!!!


    black swingarm would look good if you still haven't decided on black or polished.
    current bikes: 05 KLX110 plated big bore dual sport; 05 KTM 950 Adventure

    past bikes: 06 CRF450X tard/DS; 05 CR500AF plated SUMO/DS; 06 Berg FS650C; 01 XR650R

  24. #24
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    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.
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  25. #25
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    Default 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/w...t=DSCN3383.jpg

    http://s719.photobucket.com/albums/w...t=DSCN3386.jpg

    http://s719.photobucket.com/albums/w...t=DSCN3385.jpg

  26. #26
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    Quote Originally Posted by DBR0051 View Post
    Interesting it took a couple of hours to break down and it will be days going back.
    I know what you mean.
    That last 10% seems to take 90% of the time.


    That looks nice man........

    ..

    .
    Last edited by PingKing; 02-09-2010 at 06:20 PM.
    01 CR500af 83 XL600 hooligans 83 CR480
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  27. #27
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    That thing is really nice man. keep us posted with lots of pics!!
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  28. #28
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    Random question... How awkward is it kicking on the opposite side? Especially with a larger bore bike, I feel like I would wreck my shins
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  29. #29
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    Default 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

  30. #30
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    Default ktm

    Almost back together. I need to order some stainless bolts but it's close to done. I'm not liking the orange side # plates. I think it makes it look heavy in the back. I may try to cut down a set, or remove completly. Ideas? Should be ready for a test ride if the snow EVER melts.


    Thanks, Dave


  31. #31
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    Default ktm

    Finally figured out how to post pics. Chain is a bit too tight but nothing is final yet, just making sure everything still fit after the powder coat.






  32. #32
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    Pretty cool bike if i may add.
    ~Shawn
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  33. #33
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    hows clearance between your pipe and leg

  34. #34
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    Quote Originally Posted by roberts13 View Post
    looks so sweet 90s retro motards are where its at for me im building a ktm 360 96 mod
    black swing arm for sure
    whats the bore and stroke on the 500? Hmm these a wreaker on ebay in aus at the moe.
    I'm building a 1997 KTM 360 EXC to race! Any pointers, pics?

  35. #35
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    Very nice build!
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  36. #36
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    v-cool,friend of mine did an alum frame honda 500 this winter. lot of work but fun factor is over the top. u done good !!

  37. #37
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    Looks great.
    Any chance of posting a vid???
    01 CR500af 83 XL600 hooligans 83 CR480
    97 VFR750 CB1100F 93 Honda Sportster
    74 Suzuki Titan
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  38. #38
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    Default sick!!

    You've done great work man!
    This was just the inspiration I needed, I'm picking up a 500 on sunday and hopefully I'll have something 50% as bad(!) as your bike in a few months! I wanna see a track video!

  39. #39
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    sorry! didn't realize this was a year old!

  40. #40
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    thanks for reviving this thread! I never saw it..

    BUT HOLY SH*T!!

  41. #41
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    im gonna have to revive this thread to ask how the engine was done (powder coated, painted?) and how did it hold up? nice bike too!
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