500Sx-r (honda ktm hybrid)

[jar944]

from This:


to this:


The only custom parts are the frame mounts, head stay and the exhaust and even that isn't much work.

initial mockup



mock up spacers


relocated mounts:


rad fitment




motor cleanup & rebuild

before


during:





engine complete


head changed to single outlet


outlet plug


head stays


exhaust modifications

The can has a complete new core  & tubing (1.25")



Rear mount added, and stinger shortened for frame clearance.

[JE97]

Bad ass man!

[Super Trucker]

Awesome job JAR944, it,s been years since I,ve seen a cr500 motor in another makes frame. The stinger and pipe looked like it was quite a bit of work. I made a 03 KX 125 pipe fit, on a 04 and 06 cr125, alot of bending, cutting,and pounding to make it fit. Anyway good job on the exhaust, I know it,s alot of work.

[TotalNZ]

Wicked build, it makes so much sense to use a KTM roller don't know why you don't see it more often.

[scotty dog]

Kick arse job, love it

[nom de guerre]

Nice steely!!!

[jar944]

Wicked build, it makes so much sense to use a KTM roller don't know why you don't see it more often.

It fits with so few mods It's almost like the chassis was made for the motor.

I built this over the span of a few months, but if you started with a running engine and had all the parts, you could knock it out in a day or two at the most.

[twosmoke595]

so what year/model was the roller?

[jar944]

so what year/model was the roller?

To do it right you need a mix of parts

All the main parts swap between KTM models in the same generation.

07/08+ 2t rads
07/08+ 2t carb boot
07+ 450/505 sxf/xcf frame
07/08+ swingarm (all but the XC4)
07/08+ shock
04?+ 2t coil (or any 04+ coil with a 2t cap)

The easiest way to do it is go get a 08+ 2t roller and add the 4t frame.

What specifically did i use? honestly I'd have to look at the parts to see what years I grabbed of the shelf. I have a large pile of KTM parts and just picked through the pile to find what i wanted.

[jar944]

Looks like a KTM/CR5 conversion made it into this month's issue of dirt rider.

[Stusmoke]

Color me impressed, that looks like one BFed engine but you pulled it all together, awesome work. Even Dogger would envy you

[SachsGS]

I'd be curious to see how this conversion compares to the 500 AF conversions.