Very Nice!

Cost?

 

Well all the work was done by myself so the cost was kepted down.

But the piston was £140
Bore and replate £150
Cam £160
K&N OF EBAY £20
Samco hose £25
Carb from a mate so cheep

 

sweet. i will post dyno sheet in may, also 540 but factory kit, 8/07cam, head work, 41fcr, sx ignition box, full akra. orginaly it was 2001 400exc

 

Hay that would be good to see what the difference is:thumbup:

Just a question why do a factory kit they have a 100mm piston and shorter crank but may be the 400cc crank may work. IMO it's a bit over square and won't like to be rev'ed and you've got more change of blowing a head gasket. So the sx cdi is no good with the factory set up. I can rev my convertion to 11000rpm with no worry off it shitting the bearings.

Or are you getting the KTM hard parts kit :headscrat

The 41mm carb is a really good up grade if you want I can give you some good base settings.

I would use the a hot cam they give you much better bottom end torque.

All the best with it any way:clap:

 

nice work slinger, is that clutch cover also an "sfb" same as the ignition cover? :thumbup:

 

Cheers

Ye it is an sfb clutch cover top notch

 

how is the air filter working out? ive been thinking about doing that for a while, i hate oiling dirtbike filters

 

The K&N works great thats one of the main restriction on KTM'S the air box.
It should give you 4bhp but you will have to get it dyno'd

 

slinger, you got me wrong. i dont need advise for porting.. but good info for others.

 

OK:clap:

 

But the piston was £140
Bore and replate £150


Shops here (New Zealand) quote $2000 dollars for the Hard Parts 540 "kit"

I better track down a shop that does plating. Is it Nikasel plating?

 

or you can order one from us.

 

I'm amazed at how much HP can be free'd up on the intake side. Slinger is that a documented 4 hp increase by ditching the airbox and running a K&N?

Has anybody figured a good way to to get those HP intake gains by running a foam filter? I ride in the dirt as well as motard.

I'm converting a 525 to a Thumper Racing 570 piston, lightened flywheel by 7 oz and need to choose a cam. What cam would work well with the above set-up for motard and fast, open dirt bike riding?

 

Hay Team ftb

I do have a dyno sheet somewhere at home of that 4 bhp claim but you will have to get it dyno'd after removing the air box.

It's not really the filter that is the restriction it's the air box it's self. If your riding dirt with the same bike then a K&N filter is not the way to go.

As for the conversion your going to do because you have to use a stroked crank to get the 570cc you will not be able to rev the hard.

And the maintenance will be new main every 50 hours.

The cam you want is a HOTCAM stage one gives you good bottom end with good top end as well.

I race a 612 smr and the mains and piston has to be changed ever 10 hours so if you want more power then you get more maintenance.

But the 540 I run with a sx cdi and rev it to 11000 and it quite happy to do it.

All the best with your build and I hope you post the results up:thumbup:

 

What did you do for the carb? is it just one from a 525 SX?????

 

mine did 67hp/60nm on the wheel. carb was bored 39 to 41mm.

 

is the 400 head the same as the 520 head?

 

sweet

 

head is the same, different cam naturaly. porting is very advisable for ktm heads...

 

ok cool thanks, i went on hot cams website and the 520 stage1 cam had more lift and duration compared the 400.

 

Found this set up

But says it's only for the 07 and up models? anybody run this on a 525 or 560 SMR

http://www.ktmcyclehutt.com/ktmstore/hardparts/air_filters/KTM_air_filters.htm