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jar944 01-20-2012 12:05 PM

KTMonda CR500 450sxf conversion
I've already done 2 ktm to ktm 4t hybrids:

I got a good deal on a Craigs list CR5 and already had a 08 ktm roller in the garage. From the 2 other ktm hybrid builds I've seen it should almost be a bolt together build. The Honda parts will worked over as well, I just want to get the chassis done first.[/quote]

pivot spacers and getting the sprocket into the correct horizontal alignment.

The right rad outlet points in the wrong direction (for a 450sxf radiator)

The right outlet is perfect

The shock spring to pipe clearance may need some tweaking

Old mounts cut out and cleaned up

Re-positioned for the 500 engine and welded back in

anotherguy 01-20-2012 12:50 PM

Hmmm..................very interesting.

yzmaico 01-21-2012 05:49 PM

WOW!! I think the CR500 bike will be fantastic, I rode a Service Honda 500 awhile back and I couldn't believe the difference with the motor mounted in a new CR frame.

jar944 01-29-2012 04:55 PM

The 2t (07 125sx) radiators work with no issues

I'm just waiting on the carb boot and silencer to show up and I can finish the remaining fabrication

jar944 01-31-2012 06:18 PM

Slightly cleaner engine, allough in the process of cleanign i noticed the crank was semi submerged in oil..
I have no idea what this is

monkeys should not have tools, the stator side seal is bottomed out as well


some baking 30min @ 300

easy as Pie

On the plus side the cylinder is still on the stock bore, and it looks like the case issue is just some casting flaws. now to see how a ultrasonic cleaner does

jar944 03-24-2012 01:52 PM

cases directly out of the ultrasonic cleaner



The 2t carb boot while not perfect (the angle of the reed boot is not the same as the filter boot) it will work out.

The head, cylinder and cases cleaned up

The final case bushings machined and the head stay finished(cut and welded 250sxf stays)

It should move a bit faster now that I have most all the parts to finish

anonny 03-24-2012 06:02 PM

Very cool, thanks for posting, I just gotta ask though.... what happened to the stock motor?

edit, never mind I just spent quite a bit of time reading your links. This build would make an awesome timber sled bike.

jar944 03-24-2012 07:49 PM


Originally Posted by anonny (Post 18295718)
Very cool, thanks for posting, I just gotta ask though.... what happened to the stock motor?

edit, never mind I just spent quite a bit of time reading your links. This build would make an awesome timber sled bike.

ha, yeah this it the 3rd roller I pieced together from multiple sources. If you shop around you can do it for not much money.

dorkpunch 03-24-2012 09:47 PM

Suhweet. Friend of mine had a CR500 he did up as a trail bike, it was surprisingly useable in the woods and would climb any hill ever.

As for the timbersled- I STILL don't understand why nobodies done that yet (well, i guess I've seen some versions on a CR500 but no report as to how they perform). If I ever get my 495 pieced together and if I can ever afford a timbersled, I'll let you know how they work. Don't hold your breath though, that's a lot of ifs. :lol3

Can't wait to see how it turns out!

Rocket_Rookie 04-08-2012 09:51 AM

What a great build up!

Very neatly done, thank you for sharing with us! Please post an update of the work you have done thus far!
Since I discovered the mechanical simplicity of two strokes, I am intrigued by the Honda CR range!
Can't wait for your next post



AWM 04-09-2012 08:37 AM



jar944 04-09-2012 06:54 PM

I managed to get the cases back together, The silencer changed to a 1.25" core, and a new outlet in the head.

Rocket_Rookie 04-10-2012 09:17 AM

That engine is really shiny..... Wow.

jar944 04-10-2012 09:27 AM


Originally Posted by Rocket_Rookie (Post 18422502)
That engine is really shiny..... Wow.

especially when you compare it to how it looked a few months ago...

Sniper X 04-10-2012 03:03 PM

That is one of the best motors every built. I will never forget my first ride on the CR500R.....80mph wheelies as easily as most bike wheelie at 30mph. And the thing never seemed to run out of arm stretching power.

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