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Offline eprovenzano

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Swapping my 380 motor into a modern frame
« on: November 22, 2017, 04:35:42 AM »
I'm thinking (dreaming) about a winter project.  I'd like to swap my 380 motor into a more modern KTM frame.  Best case would be to find a KTM 250/300 smoker and swap the 380 into it.  Worst case (more effort) would be to swap the 380 into a 250 /350 /450 KTM frame.  Finding a blown stroker is much easier then finding a smoker.  I've been doing a lot of research, and am looking at making the swap.  I'm looking for a roller in the 2012 area.

Also keep in mind, I'm a cheap ass....  So I need to find an inexpensive broken bike that I can either toss the motor, or better yet sell it... 

Nothing started other then a lot of reading and a lot of dreaming... 
Eric Provenzano
2019 KTM 300 XCW TPI
2000 KTM 300 EXC (Son's)
2001 KTM 380 EXC
Sold 1991 KDX 200... fun play bike
Sold 1999 KX250
Sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125

Offline citabjockey

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Re: Swapping my 380 motor into a modern frame
« Reply #1 on: November 25, 2017, 01:56:44 PM »
Hey Eric

So just how bad is the stock 380 frame and running gear? I have thought about doing this sort of thing myself but wonder if its really going to change how much fun I have on mine. Sure, maybe I can go a tad faster and the forks will not hammer my wrists as much on the stutter bumps but overall the bikes works ok right now (except for the motor which of course is a taylor made grin generator).

That said, if you do start into the project please document the steps in detail for me!



I'm thinking (dreaming) about a winter project.  I'd like to swap my 380 motor into a more modern KTM frame.  Best case would be to find a KTM 250/300 smoker and swap the 380 into it.  Worst case (more effort) would be to swap the 380 into a 250 /350 /450 KTM frame.  Finding a blown stroker is much easier then finding a smoker.  I've been doing a lot of research, and am looking at making the swap.  I'm looking for a roller in the 2012 area.

Also keep in mind, I'm a cheap ass....  So I need to find an inexpensive broken bike that I can either toss the motor, or better yet sell it... 

Nothing started other then a lot of reading and a lot of dreaming...
« Last Edit: November 25, 2017, 06:17:25 PM by citabjockey »
Yamaha CT3, RT3, MX125, SC500, Toy Prius, Diesel F250 (it all balances out)

Offline eprovenzano

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Re: Swapping my 380 motor into a modern frame
« Reply #2 on: November 27, 2017, 11:18:29 AM »
The frame swap will drop the bikes weight plus the suspenders will be up to date...  If, and when I do make the switch, I will document as I'll need to so I can remember what the hell I did...  I'm still looking for a suitable roller, so no news yet... 
Eric Provenzano
2019 KTM 300 XCW TPI
2000 KTM 300 EXC (Son's)
2001 KTM 380 EXC
Sold 1991 KDX 200... fun play bike
Sold 1999 KX250
Sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125

Offline Coop

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Re: Swapping my 380 motor into a modern frame
« Reply #3 on: November 30, 2017, 05:39:58 AM »
I don't see too many KTM rollers for sale but maybe you will get lucky. You may have to buy a running bike and sell the engine to recoup a little of your cost. Sounds like a fun project but maybe not one for a cheapo  :D .
- Mike - Don't take life so seriously, nobody gets out alive.

Offline eprovenzano

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Re: Swapping my 380 motor into a modern frame
« Reply #4 on: December 24, 2017, 09:35:07 AM »
I found an 06 KTM 250F for $500... decided to pass...  if I'm going to go through the trouble and expense, I prefer something a little more current.
Eric Provenzano
2019 KTM 300 XCW TPI
2000 KTM 300 EXC (Son's)
2001 KTM 380 EXC
Sold 1991 KDX 200... fun play bike
Sold 1999 KX250
Sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125