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-   -   KTMonda CR500 450sxf conversion (http://www.advrider.com/forums/showthread.php?t=757835)

jar944 01-20-2012 01:05 PM

KTMonda CR500 450sxf conversion
 
I've already done 2 ktm to ktm 4t hybrids: http://www.advrider.com/forums/showthread.php?t=662808


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.

http://img.photobucket.com/albums/v6...1255Medium.jpg
http://img.photobucket.com/albums/v6...1256Medium.jpg
http://img.photobucket.com/albums/v6...1257Medium.jpg[/quote]

pivot spacers and getting the sprocket into the correct horizontal alignment.
http://img.photobucket.com/albums/v6...1280Medium.jpg

The right rad outlet points in the wrong direction (for a 450sxf radiator)
http://img.photobucket.com/albums/v6...1278Medium.jpg
http://img.photobucket.com/albums/v6...1276Medium.jpg

The right outlet is perfect
http://img.photobucket.com/albums/v6...1277Medium.jpg

The shock spring to pipe clearance may need some tweaking
http://img.photobucket.com/albums/v6...1273Medium.jpg
http://img.photobucket.com/albums/v6...1274Medium.jpg

Old mounts cut out and cleaned up
http://img.photobucket.com/albums/v6...1282Medium.jpg

Re-positioned for the 500 engine and welded back in
http://img.photobucket.com/albums/v6...1289Medium.jpg

anotherguy 01-20-2012 01:50 PM

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

yzmaico 01-21-2012 06:49 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 05:55 PM

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

http://img.photobucket.com/albums/v6...1326Medium.jpg
http://img.photobucket.com/albums/v6...1327Medium.jpg

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

http://img.photobucket.com/albums/v6...1329Medium.jpg

jar944 01-31-2012 07:18 PM

Slightly cleaner engine, allough in the process of cleanign i noticed the crank was semi submerged in oil..
http://img.photobucket.com/albums/v6...1344Medium.jpg
crack
http://img.photobucket.com/albums/v6...1332Medium.jpg
I have no idea what this is
http://img.photobucket.com/albums/v6...1341Medium.jpg
http://img.photobucket.com/albums/v6...1340Medium.jpg

monkeys should not have tools, the stator side seal is bottomed out as well
http://img.photobucket.com/albums/v6...1353Medium.jpg

cleaner
http://img.photobucket.com/albums/v6...1367Medium.jpg
http://img.photobucket.com/albums/v6...1369Medium.jpg

some baking 30min @ 300
http://img.photobucket.com/albums/v6...1370Medium.jpg

easy as Pie
http://img.photobucket.com/albums/v6...1371Medium.jpg

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 02:52 PM

cases directly out of the ultrasonic cleaner

before
http://img.photobucket.com/albums/v6...1379Medium.jpg

after
http://img.photobucket.com/albums/v6...1388Medium.jpg
http://img.photobucket.com/albums/v6...1387Medium.jpg
http://img.photobucket.com/albums/v6...1381Medium.jpg

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.

http://img.photobucket.com/albums/v6...1393Medium.jpg


The head, cylinder and cases cleaned up

http://img.photobucket.com/albums/v6..._1439Small.jpg
http://img.photobucket.com/albums/v6..._1440Small.jpg
http://img.photobucket.com/albums/v6..._1441Small.jpg
http://img.photobucket.com/albums/v6...1506Medium.jpg
http://img.photobucket.com/albums/v6...1504Medium.jpg
http://img.photobucket.com/albums/v6...1499Medium.jpg

The final case bushings machined and the head stay finished(cut and welded 250sxf stays)
http://img.photobucket.com/albums/v6...1507Medium.jpg
http://img.photobucket.com/albums/v6...1515Medium.jpg
http://img.photobucket.com/albums/v6...1518Medium.jpg
http://img.photobucket.com/albums/v6...1520Medium.jpg

It should move a bit faster now that I have most all the parts to finish
http://img.photobucket.com/albums/v6...1523Medium.jpg

anonny 03-24-2012 07:02 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 08:49 PM

Quote:

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 10:47 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 10:51 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

Regards,

Rocket_Rookie

AWM 04-09-2012 09:37 AM

:ear


BBBbbbrrraaaappppp!!!

jar944 04-09-2012 07:54 PM

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

http://img.photobucket.com/albums/v6...1564Medium.jpg
http://img.photobucket.com/albums/v6...1566Medium.jpg
http://img.photobucket.com/albums/v6...1565Medium.jpg

Rocket_Rookie 04-10-2012 10:17 AM

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

jar944 04-10-2012 10:27 AM

Quote:

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 04:03 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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