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Old 01-20-2012, 12:05 PM   #1
jar944 OP
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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.



[/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
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Old 01-20-2012, 12:50 PM   #2
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Hmmm..................very interesting.
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Old 01-21-2012, 05:49 PM   #3
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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.
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Old 01-29-2012, 04:55 PM   #4
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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

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Old 01-31-2012, 06:18 PM   #5
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Slightly cleaner engine, allough in the process of cleanign i noticed the crank was semi submerged in oil..

crack

I have no idea what this is



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


cleaner



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
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Old 03-24-2012, 01:52 PM   #6
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cases directly out of the ultrasonic cleaner

before


after




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
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Old 03-24-2012, 06:02 PM   #7
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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.
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anonny screwed with this post 03-24-2012 at 06:31 PM
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Old 03-24-2012, 07:49 PM   #8
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Quote:
Originally Posted by anonny View Post
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.
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Old 03-24-2012, 09:47 PM   #9
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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.

Can't wait to see how it turns out!
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Old 04-08-2012, 09:51 AM   #10
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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,

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Old 04-09-2012, 08:37 AM   #11
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BBBbbbrrraaaappppp!!!
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Old 04-09-2012, 06:54 PM   #12
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I managed to get the cases back together, The silencer changed to a 1.25" core, and a new outlet in the head.



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Old 09-01-2012, 08:44 AM   #13
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Originally Posted by jar944 View Post
I managed to get the cases back together, The silencer changed to a 1.25" core, and a new outlet in the head.



Hi.i m doing a cr500 ktm project too. 94 engine with a sxf 450 2008 frame. It s welded painted put together almost completly. I m waiting for the air boot and griphics. I notice that the cdi u r using ( the part attached to the frame and connected to the spark plug) is not the original one and fit perfect on the frame mount. Where does it come from? Also my brake pedal is a little too close from the case, did u have to bend it too? I really like ur blog it help me a lot on my builng. I should have it running next week end. My engine was nothing like urs, just did top end. I also have different radiators, from a xc i think, so i ll run some different hose and use the two holes on the head. I didnt have to mod much the pipe and silenceur either. Lucky on that one. Thx
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Old 09-04-2012, 05:31 AM   #14
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Quote:
Originally Posted by flying frenchie View Post
Hi.i m doing a cr500 ktm project too. 94 engine with a sxf 450 2008 frame. It s welded painted put together almost completly. I m waiting for the air boot and griphics. I notice that the cdi u r using ( the part attached to the frame and connected to the spark plug) is not the original one and fit perfect on the frame mount. Where does it come from? Also my brake pedal is a little too close from the case, did u have to bend it too? I really like ur blog it help me a lot on my builng. I should have it running next week end. My engine was nothing like urs, just did top end. I also have different radiators, from a xc i think, so i ll run some different hose and use the two holes on the head. I didnt have to mod much the pipe and silenceur either. Lucky on that one. Thx
You mean the coil (not the CDI) the coil is the stock KTM, with a 2t plug cap.

Yes the brake pedal was bent out a couple mm to clear the case.
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Old 04-10-2012, 09:17 AM   #15
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That engine is really shiny..... Wow.
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