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I started this project a while ago, but figured it would be neat to show progress up until today.
Started as a 2004 KTM 250 EXC, in pretty decent shape.
I rode the hell out of it, was a GREAT trail bike. Never really had to do much of anything to it. However, I can't leave things alone.
So first up, converted the body to 2012+
Picked up a set of body work, tank, seat, and subframe on ebay.
Had a mount machined to weld on the original frame to attach the new subframe
And welded and painted.
Made a couple simple brackets to attach the silencer
And suddenly looks much better
I hadn't ever planned on doing a supermoto, but I think I saw some pics online and was hooked.
Found a set of Behr 3.5/4.25 with a cush drive on ebay in Ireland. Not in great shape.. the spokes are rusted terribly, but they're straight and were cheap.
The 4.25 rear fit eaaaasssyy.
Spooned on some tires.. (loads of fun) and there we were.
Realized quickly that range was quite limited with the small tank, and power delivery was pretty garbage.. so snagged a lectron to help with fuel consumption and smooth out power delivery. Also grabbed a larger tank.
Then realized that the stock brakes were sketchy at best... so EBC 320 rotor and relocation bracket.
Had a bit of a lowside slide on some twisties.. tore up the stock swingarm pretty good, ate up the chain guide bracket as well.. soooo helllllo ebay.
Around this time, realized it was probably due for a top end... so did the logical thing and got a 300sx kit for the 2014. This model has better porting and power than the one that is actually supposed to go on my motor.. and wasn't difficult to adapt. New motor mounts, some different studs, change some power valve actuator parts.
Figured while I'm in here, may as well upgrade the stator.. grabbed a trail-tech one.
The 300SX kit i got came with the new model CDI, figured I'd wanna use that, to gain whatever updating, plus they have 2 different maps. This took a little more wiring. Went ahead and got the OEM parts to relocate the CDI to where it goes on the newer models, as well as installed a wiring harness off a newer model 2 stroke. Converted it to DC as well, using a trail-tech reg/rec.
And again.. while I've got it apart, the old rads were looking pretty ratty, grabbed some chinese aluminum ones. Had great luck with these on a couple other bikes.
Got everything buttoned up, and didn't really do anything else for a few months.
Few weeks ago, I decided I'd like to change it up.. new plastics and graphics.
I was much happier with the white... but then realized the whole thing was looking kinda ratty. Frame was rough, etc etc.
Decided to finally get it RIGHT for street use.. been researching wiring for a while now, finally found a harness I wanted. I know a lot of people use the Tusk kits, but figured i'd rather keep it uhh.. stock(lol) as possible. Picked up an EXC harness from a late model 4 stroke, and OEM combo switch.. Now I'll finally have signals, a key switch, hi/lo beam, and indicator lights. I really like the idea of having all original KTM wiring.
Stripped the OEM powder from the frame.
Did a little masking, and shot KTM orange at it.
Decided since I already had it apart, should get a set of the 14mm clamps to help handling.
Going to be using this powder on a bunch of stuff. It's a satin black, with a very fine silver metallic in it.
Started to put the clamps and forks back on, and realized most of my stock bolts looked awful, very rusty... soo more powder. Was tempting to order all new bolts from KTM, but the price threw me.
This is after they've seen a torque wrench, they'll hold up just fine. The new factory bolts look worse than this after having a wrench on them.
Figured I should do something with the calipers while I had them off. Needed to rebuilt the rear caliper and it's master cylinder anyways.
The rest of the covers will get done too, as well as the bolts... this is just the first one. They're all getting that same satin black.
Pegs obviously looked bad, just like everything else did.
Annnd that's current as of today. I've got a lot more stuff to powder, and some stuff to replace. Once it's more together, I'll start figuring out how to make that new harness work as well.
LOTS of stuff left to do, but I'll try and keep this updated.
Started as a 2004 KTM 250 EXC, in pretty decent shape.

I rode the hell out of it, was a GREAT trail bike. Never really had to do much of anything to it. However, I can't leave things alone.
So first up, converted the body to 2012+
Picked up a set of body work, tank, seat, and subframe on ebay.

Had a mount machined to weld on the original frame to attach the new subframe

And welded and painted.

Made a couple simple brackets to attach the silencer

And suddenly looks much better

I hadn't ever planned on doing a supermoto, but I think I saw some pics online and was hooked.
Found a set of Behr 3.5/4.25 with a cush drive on ebay in Ireland. Not in great shape.. the spokes are rusted terribly, but they're straight and were cheap.

The 4.25 rear fit eaaaasssyy.

Spooned on some tires.. (loads of fun) and there we were.

Realized quickly that range was quite limited with the small tank, and power delivery was pretty garbage.. so snagged a lectron to help with fuel consumption and smooth out power delivery. Also grabbed a larger tank.

Then realized that the stock brakes were sketchy at best... so EBC 320 rotor and relocation bracket.

Had a bit of a lowside slide on some twisties.. tore up the stock swingarm pretty good, ate up the chain guide bracket as well.. soooo helllllo ebay.


Around this time, realized it was probably due for a top end... so did the logical thing and got a 300sx kit for the 2014. This model has better porting and power than the one that is actually supposed to go on my motor.. and wasn't difficult to adapt. New motor mounts, some different studs, change some power valve actuator parts.

Figured while I'm in here, may as well upgrade the stator.. grabbed a trail-tech one.

The 300SX kit i got came with the new model CDI, figured I'd wanna use that, to gain whatever updating, plus they have 2 different maps. This took a little more wiring. Went ahead and got the OEM parts to relocate the CDI to where it goes on the newer models, as well as installed a wiring harness off a newer model 2 stroke. Converted it to DC as well, using a trail-tech reg/rec.

And again.. while I've got it apart, the old rads were looking pretty ratty, grabbed some chinese aluminum ones. Had great luck with these on a couple other bikes.

Got everything buttoned up, and didn't really do anything else for a few months.
Few weeks ago, I decided I'd like to change it up.. new plastics and graphics.

I was much happier with the white... but then realized the whole thing was looking kinda ratty. Frame was rough, etc etc.


Decided to finally get it RIGHT for street use.. been researching wiring for a while now, finally found a harness I wanted. I know a lot of people use the Tusk kits, but figured i'd rather keep it uhh.. stock(lol) as possible. Picked up an EXC harness from a late model 4 stroke, and OEM combo switch.. Now I'll finally have signals, a key switch, hi/lo beam, and indicator lights. I really like the idea of having all original KTM wiring.

Stripped the OEM powder from the frame.

Did a little masking, and shot KTM orange at it.


Decided since I already had it apart, should get a set of the 14mm clamps to help handling.


Going to be using this powder on a bunch of stuff. It's a satin black, with a very fine silver metallic in it.

Started to put the clamps and forks back on, and realized most of my stock bolts looked awful, very rusty... soo more powder. Was tempting to order all new bolts from KTM, but the price threw me.

This is after they've seen a torque wrench, they'll hold up just fine. The new factory bolts look worse than this after having a wrench on them.

Figured I should do something with the calipers while I had them off. Needed to rebuilt the rear caliper and it's master cylinder anyways.

The rest of the covers will get done too, as well as the bolts... this is just the first one. They're all getting that same satin black.

Pegs obviously looked bad, just like everything else did.

Annnd that's current as of today. I've got a lot more stuff to powder, and some stuff to replace. Once it's more together, I'll start figuring out how to make that new harness work as well.
LOTS of stuff left to do, but I'll try and keep this updated.