2011 KTM380sx

[CHOPPA]

Against my best judgement I have decided to create this thread before I have even picked up the bikes but I have paid for them both in full and will be picking them up on Anzac day. I have wanted to do this project for a while and when they both come up at the same time it was a sign!! It was a bit hard trying to link up both purchases as I didnt want one and not the other.....

So....

I have purchased the 2011 KTM 350SXF from Flyin CR that unfortunately exploded and I have purchased a late model KTM 380SX

If you havnt guessed yet ill be putting the 380sx motor in the SXF chassis to make my ultimate TT machine. If anyone needs some parts for a 350SXF engine there are a few bits there that I intend to sell off to put some money towards the conversion. I will also have a 380 rolling chassis to sell off as parts.

I am considering doing it myself but I do know a guy in Tauranga that does CR500AFs he done the black one on trade me and he said if I dropped both bikes off he would do the complete job for me.

I will post pictures as I get them

[ktm84mxc]

Now that will be a weapon it shouldn"t be to hard to see if the engine mounts match up most critical will be the swingarm bolt, front engine mounts use a plate so easy to make up a new set same for the head stay.
There's a motard Husaberg 300 with a 380 engine in it reputed to put out 70hp racing in europe it's on the Ktmtalk web site it has to be heard.

[Jinxycat]

sweet, i can't wait, hope you can keep us up to date with pic's and stuff

[CHOPPA]

Its not going to be a walk in the park.... There is not much I can find on the subject but it seems that the swingarm bolt is a 14mm on the 380 and 16mm on the 350 so I think ill end up spliting the cases to drill it properly. The is a dowl in there that will need to be replaced. The 350 dowl looks to fit in though.

I was intending on rebuilding the 380 so I dont mind pulling it apart

[CHOPPA]

Found this from a guys that built a 2007 model....

http://www.kiwibiker.co.nz/forums/images/icons/icon1.gif Re: ktm 450 with 380 2 stroke engined hybrid 2007
<!-- / icon and title --><!-- message -->i forgot phone number daytime 01477 500757, erm the hardest part is finding a 380 exc that you can but for not too silly £, you have to modify the radiators cut the engine mounts off the frame and make new ones ,bore out the swingarm spindle hole in the engine,weld them engine mounts on after you have set the engine in just the right position, then make the exhaust mount bracket ,make the head stays and change the carb rubber for the 2 stroke one, change the throttle, and fit the hydraulic clutch and mount the topcoil/cdi setup, and rebuild the motor and anything that needs changeing change it! not too bad realy, as i said finding the 380 engine is the problemhttp://www.kiwibiker.co.nz/forums/gfx/emoticon/icon_lol.gif

[scott411]

good luck, with this, suprises me a 2011 model is not worth fixing tho, must have been a major,

you may have to offset bore the swing arm pivot in the cases, so will pay to to the research and test fitting before you do that,


still, any late model 450 will blow it away, but it will be fun tho have something different on the line, and nothing sounds quite as good as a big bore 2 stroke on the pipe out of a corner,

[CHOPPA]

good luck, with this, suprises me a 2011 model is not worth fixing tho, must have been a major,

you may have to offset bore the swing arm pivot in the cases, so will pay to to the research and test fitting before you do that,


still, any late model 450 will blow it away, but it will be fun tho have something different on the line, and nothing sounds quite as good as a big bore 2 stroke on the pipe out of a corner,

Yeah I do like 2 strokes, actually I love the new 450s too but I like being different.

There is no doubt the 450s are the top dog or they would have kept producing these

[F5 Dave]

Hey I hope you haven't spent all your bucket money.

If you need engineering & welding, pipe mods etc Damon from Cycleworks is still operating in upper upper hutt.

[White trash]

Hey I hope you haven't spent all your bucket money.

If you need engineering & welding, pipe mods etc Damon from Cycleworks is still operating in upper upper hutt.

He came round my place and saw the awesomeness that is the TSFZR 3LN RR SPS and ran with his tail between his legs mate. Fuggin big gurls blouse that he is............

[Pornstar]

He came round my place and saw the awesomeness that is the TSFZR 3LN RR SPS and ran with his tail between his legs mate. Fuggin big gurls blouse that he is............

He knows how to charge though

[Jay GTI]

still, any late model 450 will blow it away, but it will be fun tho have something different on the line, and nothing sounds quite as good as a big bore 2 stroke on the pipe out of a corner,

How dare you try and sully this project with such ridiculous things as logic and sense!!

Sounds awesome, was talking to a workmate who had a 380sx as his first bike. He chopped it for a 125 very, very quickly...

[CHOPPA]

How dare you try and sully this project with such ridiculous things as logic and sense!!

Sounds awesome, was talking to a workmate who had a 380sx as his first bike. He chopped it for a 125 very, very quickly...

We will see if Scottys 450 blows it away at the TT....

[Flicks]

What's damaged In the engine?

[noobi]

What's damaged In the engine?

http://www.kiwibiker.co.nz/forums/showthread.php/148725-When-good-bikes-go-bad

[CHOPPA]

Bikes all finished. Just gotta put the blank off plates where the fuel pump was and put in a new petcock.

Bike needs new wheel bearings so wont ride till I can get those other wise id have sorted out the petcock tonight and rode it tomorrow.

Once I have taken it for a blast ill pull it apart to paint the frame up properly and give the motor a clean up and a rebuild. Mind you it has so much bloody compression!

I swear this bike was made for one of these engines. Everything fits perfect all you have to do is move 2 engine mounts

[noobi]

That was quick.

PICTURES

[CHOPPA]

Yeah it was so easy it wasnt funny. I have pictures but the bike wasnt that clean when I got it and I didnt clean it cause I was just sorta gonna see how hard it was gonna be then all of a sudden it was done.

The engine needs a good clean too so ill either take some pics once I get it more dirty or ill wait till I paint the frame etc cause its just in primed atm

[crazyxr250rider]

Always wanted to do something similar, as noobi said pics asap!

[CHOPPA]

Got it all going/mocked up but now its stripped down again. Its at the engineers having the mounts fabricated so its done right. Sold the 380 rolling chassis so have splashed out on new graphics. Nothing too loud, sorta look like 2012 graphics. Got a few new plastics, new FMF pipe and silencer, parts to rebuild engine.

Will do a good picture trail once I get it back from the engineers

[Jay GTI]

Damn you DAMN YOU for making me wait, I really want to see pics of this bike... and want to know what it rides like, so I know whether or not to buy a spare 380 engine for any potential grenade issues of my own... :)

[Pornstar]

Farrk man, get some 2013 plastics, the shrouds and fender look "da bomb". which reminds me, when ya comin up for a scoot at my place?

[CHOPPA]

Farrk man, get some 2013 plastics, the shrouds and fender look "da bomb". which reminds me, when ya comin up for a scoot at my place?


Oh shit dont tell me they fit??? Mate should be good to go in about 2-3 weeks just waiting on parts from the states

[barty5]

Oh shit dont tell me they fit??? Mate should be good to go in about 2-3 weeks just waiting on parts from the states

2013 wont have changed will they ????

[CHOPPA]

2013 wont have changed will they ????


Yeah man they look like Dungeys 450

http://www.google.co.nz/imgres?q=ryan+dungey+450&hl=en&safe=active&sa=X&biw=1024&bih=566&tbm=isch&prmd=imvnso&tbnid=4n_ZbnII6aShvM:&imgrefurl=http://blog.motorcycle.com/2012/01/05/manufacturers/ktm/2012-ktm-450-sx-f-factory-edition-ryan-dungey-replica-announced/&docid=dyBicH8fAkJpDM&imgurl=http://blog.motorcycle.com/wp-content/uploads/2012/01/010512-2012-ktm-450-sx-f-factory-edition-1.jpg&w=732&h=487&ei=OlanT76QHYrAiQeovtHGAw&zoom=1&iact=rc&dur=391&sig=115009793168249429671&page=1&tbnh=114&tbnw=178&start=0&ndsp=15&ved=1t:429,r:12,s:0,i:97&tx=116&ty=76

[Pornstar]

http://www.motoverte.com/article/article/voici-la-ktm-450-sx-f-factory-replica-2013-une-serie-limitee-sur-bases-de-modele-2013-c-dr-63893-1-v4zoom.jpg
I'd say so

[CHOPPA]

Got a little bit done this weekend. Just waiting on the piston kit to turn up and got some other engine parts getting sand blasted or some sorta blasted. Missus is not happy losing her sun room hahaha

[Boo]

Sitting high Sloane, is that because the rear of the kick starter housing is to big to fit into the bottom rail. Its pretty hard to see how youve got the swing arm bolt and motor hooked up. Should be nice ride. Don't know much about these rides, are the frames pretty good. In your opinion is it worth the trouble to considering the 300 is an excellant bike. Ive seen the new road legal 350 man you could drop a 380 and have a mean tard. oh its Richard from Hams. Nice bike sloane, fuck youd be able to clean up on that.

[CHOPPA]

Sitting high Sloane, is that because the rear of the kick starter housing is to big to fit into the bottom rail. Its pretty hard to see how youve got the swing arm bolt and motor hooked up. Should be nice ride. Don't know much about these rides, are the frames pretty good. In your opinion is it worth the trouble to considering the 300 is an excellant bike. Ive seen the new road legal 350 man you could drop a 380 and have a mean tard. oh its Richard from Hams. Nice bike sloane, fuck youd be able to clean up on that.

Oh heya mate! It fits in real nice. The 350 engine sits very low compared the 2 strokes you can see in pictures. When the barrel is on it just clears the down tube so it wont go any lower but we measured the angle that the engine sat in the original chassis and made it sit in exactly the same angle in the new chassis. It bolts in perfectly between the swingarm with no mods.

The 300 is nice the 380 is a hole different animal. The 380 is a pretty rear engine, not quite as much HP as the 500 but a bit revvier so it should be a shit load of fun. Last 2 stroke to win the open class world title.....

I wouldnt buy a 350 4 stroke, 450 all the way

[Boo]

Is there much difference to the 4t and the old school 2t. I understand the concept in terms of a smooth and tractable power delivery. Having owned a KX 500, in your opinion is the 4t and the direction there going, leading to a bike that costs alot of money to maintain.
It seems veterans like myself are starting to look for a more reliable and less maintance free bike, Ive never riden any of the later stuff.
Having riden both 2t and 4t what is it that makes it better. Sorry to go off topic, but I would reaaly like to know. thanks

[CHOPPA]

Is there much difference to the 4t and the old school 2t. I understand the concept in terms of a smooth and tractable power delivery. Having owned a KX 500, in your opinion is the 4t and the direction there going, leading to a bike that costs alot of money to maintain.
It seems veterans like myself are starting to look for a more reliable and less maintance free bike, Ive never riden any of the later stuff.
Having riden both 2t and 4t what is it that makes it better. Sorry to go off topic, but I would reaaly like to know. thanks

I had a ride on a 2012 RMZ450 the other day and they are amazing, you have so much feel on the throttle the injection is so sharp there is heaps of power but so smooth they rev and the clutch is mint gear box is effortless.
Big 2 strokes (I have owned them all) the old chassis are shit the brakes dont work. In a modern chassis they are much better but the engines dont rev like a 450 and the window of power is much smaller then on a 450. You end up riding the 500 in a gear higher because as soon as you hit the power you have to change so 1st and 2nd are seldom used. Then you run into problems with the heavy clutch and the gear boxes are not nearly as smooth.

Thats if your trying to race them.... I dont know too many people that have actually been silly enough to race their 500s so its not as much of an issue. For the everyday rider then 2 strokes are really easy to maintain and they also hold better value. If you have a CR500AF or this for example because they are a little bit special they hold their value quite well. Look at the CR500AFs you see on trade me around 8k That would get you a 2011 CRF450!

Another good thing about the big bore 2 strokes is the look at me factor that I love hahahaha To be honest I just like doing projects and after I spend so much time on a bike I dont have the heart to ride it cause I wreck shit. It will be for sale in a few weeks

[Boo]

Yes very valid points, but if you look at a late model 450, and there power delivery, and the power delivery of a big bore 2t they dont match. All frames now days are built to handle that type of power. When faced with any big bore 2t, the frames can't handle the hard hitting power. I think not handle is too harsh a word but do you get what I'm saying. Therefore any conversation where a 2t is put into a late model frame will not handle as well due to stresses and flex not originally spcified in the frame. I don't won't to put your build down and many would not know have the ability to ride the bike to that level. I've been contempllating the issue for awhile. To really have a bike with such a conversation, some thought must be taken into consideration where by the motor has a more linear power delvery. Porting could possibily help achieve this, while still retaining the 2t reliabilty and character they have.

[CHOPPA]

Yes very valid points, but if you look at a late model 450, and there power delivery, and the power delivery of a big bore 2t they dont match. All frames now days are built to handle that type of power. When faced with any big bore 2t, the frames can't handle the hard hitting power. I think not handle is too harsh a word but do you get what I'm saying. Therefore any conversation where a 2t is put into a late model frame will not handle as well due to stresses and flex not originally spcified in the frame. I don't won't to put your build down and many would not know have the ability to ride the bike to that level. I've been contempllating the issue for awhile. To really have a bike with such a conversation, some thought must be taken into consideration where by the motor has a more linear power delvery. Porting could possibily help achieve this, while still retaining the 2t reliabilty and character they have.


I know you have done several CR500AFs so your talking from experience but the KTM is a bit different to the hondas as they still develop 2 strokes and they use the same frames and it shows by just how easy it was to put this engine in and everything lines up perfectly as if it were made to fit. The power is the same as a 450 so there is certainly not too much power to overcome the frame.

There is no way that a 2 stroke is going to create extra stress in a frame designed for a 4 stroke, there is no hit on a 500 2 stroke its just like a big 4 stroke but they dont rev out.

The modern frames are far stiffer than anything that a 500cc every came out in

[takitimu]

Do you think the vibration of the 2T vs 4T is a factor in the frames cracking ?, mates CR500 transplant has cracked the frame.

[doddzee]

Do you think the vibration of the 2T vs 4T is a factor in the frames cracking ?, mates CR500 transplant has cracked the frame.

Would say vibration would be one of the contributers, more so in an alloy frame due to the way aluminum fatigues.

Another big bore in a KTM frame http://ktmtalk.com/index.php?showtopic=442105&st=120

Awesome build Choppa.

[CHOPPA]

Would say vibration would be one of the contributers, more so in an alloy frame due to the way aluminum fatigues.

Another big bore in a KTM frame http://ktmtalk.com/index.php?showtopic=442105&st=120

Awesome build Choppa.


Cheers mate! That looks good but I dont think I could bastardise a bike by putting a honda engine in a KTM just seems wrong! :)

[Flicks]

The frame should be fine as KTM still use steel frames so less flex then aluminium.

[Jay GTI]

Please don't sully this thread by making it yet another bloody 2T vs 4T debate.

This bike is awesome, simply because it's awesome.

[Stylo]

Please don't sully this thread by making it yet another bloody 2T vs 4T debate.

This bike is awesome, simply because it's awesome.

Don't think the 2T vs 4T debate is going to end anytime soon mate , it's healthy and helps keep these threads alive .

[Jay GTI]

Don't think the 2T vs 4T debate is going to end anytime soon mate , it's healthy and helps keep these threads alive .

True, it will never end... but I really want to read about this bike, not why a 500 2T in a Honda alloy frame is/isn't a good idea.

[CHOPPA]

Just bolted a few more things on

[Crasherfromwayback]

Bet my 30 year old YZ465 is faster in a straight line!

At the first corner, the bet stops! :bleh:

[CHOPPA]

Bet my 30 year old YZ465 is faster in a straight line!

At the first corner, the bet stops! :bleh:

I dont know man, with those clunky old gearboxes ill give you a shot!

[Crasherfromwayback]

I dont know man, with those clunky old gearboxes ill give you a shot!

I'll start in 3rd. Only need a gear change or two to roost in your face.











Maybe.

[F5 Dave]

One end of Kent Terrace to the other? Basin on knobblies could be interesting.

[Boo]

When you sat the motor in the frame and lined up the front and rear sprockets, where did the motor sit with the bottom rails. Did you put the engine mounts on the the rails to lift the motor enough to reach the air box without mods.
The motor looks to be clocked forward, did this allow enough room to put the chamber though the Y. I would be careful with that as you may have problems fitting the pipe as it will turn the pipe down and it may run lower under the bottom rails.
Did you try to sit it in the frame lower, it looks as though the kicker would hit where the swing arm bolt and frame bolt on. I ran a set of 20mm triples on my build and needed to pay attention to if there was clearance when the fork bottomed out. Man thats a big clutch the piston looks small in comparsion.

[CHOPPA]

When you sat the motor in the frame and lined up the front and rear sprockets, where did the motor sit with the bottom rails. Did you put the engine mounts on the the rails to lift the motor enough to reach the air box without mods.
The motor looks to be clocked forward, did this allow enough room to put the chamber though the Y. I would be careful with that as you may have problems fitting the pipe as it will turn the pipe down and it may run lower under the bottom rails.
Did you try to sit it in the frame lower, it looks as though the kicker would hit where the swing arm bolt and frame bolt on. I ran a set of 20mm triples on my build and needed to pay attention to if there was clearance when the fork bottomed out. Man thats a big clutch the piston looks small in comparsion.


Na mate as said before everything lines up perfect. The pipe fits like it was made for the frame it even bolts up to the standard mounts and requires absolutely no modification except for a bottom mount point. This is not like a cut and shut CR500AF.... All will make sense to you when you see the cylinder and pipe fitted. Check this one out to give you an idea.....

[F5 Dave]

So like they made their first 4 strokes to fit into existing frames with minimal modification & then latter models kept the same architecture, hence swapping back is still an open choice. I like it.

[CHOPPA]

So like they made their first 4 strokes to fit into existing frames with minimal modification & then latter models kept the same architecture, hence swapping back is still an open choice. I like it.

It would certainly appear that way mate. To be honest it looks like because they have continued with the development of 2 strokes that the 2 stroke and 4 strokes are almost identical apart from the cradle. So they keep the same sprocket spacing and rear engine mount, swingarm spacing. The only thing we had to move were the bottom and front engine mounts. The front by about 10mm the bottom by about 20mm. The 380 air boot even fits into the 350 air box and the 380 radiators bolt up to the 350 frame.

We had CEMAC engineering in Wellington do the work, he did a really nice job

[Crasherfromwayback]

.

We had CEMAC engineering in Wellington do the work, he did a really nice job

He sure does! Bike looks great mate!

[F5 Dave]

. . .and the 380 radiators bolt up to the 350 frame. . .
Next you'll say they'd probably fit my GasGas 300.:laugh:

(they are a cross over part, so yes they do!)

[Boo]

Looks real nice chopper, that front wheel looks as though it could get close to the front tyre, specially when you jump it
LOL!
Sorry about the off topic shit started, it wasn't meant to be that way. Your opinion was valued by myself as you have the experience of riding alot of different bikes. I still think your wrong LOL!, but all and all much appreciated. Oh go look over in the motard section, my bikes over there. Look forward to seeing it when its finished.

[Taz]

Looks real nice chopper, that front wheel looks as though it could get close to the front tyre, .

Hopefully the front wheel is very very close to the front tyre, it works best that way. :lol:

[Boo]

Not when off a big jump and bottoms out and hits the pipe.

[CHOPPA]

Looks real nice chopper, that front wheel looks as though it could get close to the front tyre, specially when you jump it
LOL!
Sorry about the off topic shit started, it wasn't meant to be that way. Your opinion was valued by myself as you have the experience of riding alot of different bikes. I still think your wrong LOL!, but all and all much appreciated. Oh go look over in the motard section, my bikes over there. Look forward to seeing it when its finished.

Thats looking real nice Richard, I thought you were gonna motard the 01 cause the chassis was stiffer??

The 380 is the go for me mate, more original :bleh: Check out this one that was run in the german supermoto championships


"this bike will compete in the top class of the german supermotard championship 2011. pilot is an ex-german champion who is sick of the 4stroke bikes. handmade exhaust, lots of other on-off stuff, engine from a 380 with nearly 70hp

the rider also tested a kx 500 (standard and modded to 540) but he said these machines are reving up too sluggish. furthermore the huge pistons of these bikes (BANG BANG) bring a lot of disturbance to the suspension. so the 380 was a compromise of quick reving and being neutrally to the suspension. he also tested a 300 but he was missing the extra bit of punch that the 380 seems to have. he stated that with a 300 in original condition he was able to do nearly the same lap times as with his 650 4T last season. i´m also curious what the season will bring. 4 spare engines are awaiting their duty... "

[Crasherfromwayback]

Looks choice!

[CHOPPA]

Looks choice!

Pretty sure I saw someone in Christchurch racing a 380 at the BEARS meeting

[Crasherfromwayback]

Pretty sure I saw someone in Christchurch racing a 380 at the BEARS meeting

380 would certainly seem to me (and others obviously) the ideal size for a smoker. Pity they didn't catch on.

[Boo]

Yeah seen that one, the 07 is just so much better to ride. I dont think theres the ideal smoker to ride as alot of things have to come into consideration.
Piston size and speed is a factor but torque and power can be utilised in many different ways by porting.Its just cheaper to do on a 2t.
Because big bore 2ts are not being made, availabilty of parts will always pose problems. In a motard/offroad application technology rules, its hard to keep up with motor with all the bells and whistles verses something built 20 years ago.
But at the end of the day we chose to ride what we like, its getting out there and doing it. For me its about enjoying my ride and having a bit of fun eh!.
If I can manage to beat a few 4ts even better, if I don't Ill still be happy giving it ago.
Be awesome to see you kick some 4ts butt on that thing, nothing like hearing a big bore at full song. cheers mate.

[CHOPPA]

Got a bit further. Just waiting on some seals and a new magneto cover cause it had a crack. Fitted the pipe up just to see how it fits.....

[green machine]

Hey Choppa,just came accross this and thought of this thread
http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/brakes/auction-477707964.htm

[CHOPPA]

Hey Choppa,just came accross this and thought of this thread
http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/brakes/auction-477707964.htm

Cheers mate, yeah I have seen that. The gaskets would have been good but not much else and he only wants to sell as a package...

[F5 Dave]

Looking good. Nice floorboards.

[CHOPPA]

Havnt done too much lately, new Superbike to build and started new job but not much left to do now...

[Pornstar]

Lookin Tre' Massive man.

[browny]

I notice the edition of the trophy, is that so it knows what it's gotta win.:first: and how do you get away with having it in side on the polished floor, my missus would have a shit fit

[CHOPPA]

I notice the edition of the trophy, is that so it knows what it's gotta win.:first: and how do you get away with having in side on the polished floor, my missus would have a shit fit

lol yeah I noticed that in the shot. I brought that one so I could put it subtly in the shot so people think im the man :apumpin:

Yeah the missus wasnt too keen.... It wasnt too bad though because I just brought in one part at a time haha

[browny]

Cunning. Looks good

[CHOPPA]

Nearly done, new seat cover going on... Need a couple of tiny things like bleed clutch fill with water fill with petrol put on new chain test ride then new tyres and brake pads and we are good to go!

[Crasherfromwayback]

Nearly done, new seat cover going on... Need a couple of tiny things like bleed clutch fill with water fill with petrol put on new chain test ride then new tyres and brake pads and we are good to go!

Looks real nice!

[Stylo]

Love your new Scooter too.

KTM stopped making the 380's when ?

[CHOPPA]

Love your new Scooter too.

KTM stopped making the 380's when ?

2002 Was the last year.... They were the last 2 stroke to win the open world title in 96 I think - Shayne King

[CHOPPA]

Love your new Scooter too.

KTM stopped making the 380's when ?

haha just sold my Scooter today!

[CHOPPA]

http://www.facebook.com/photo.php?v=10151850539940487&ref=notif&notif_t=video_comment

[Stylo]

Sounds awesome , good work , how many hours on the motor ?

And you've sold it ??

[CHOPPA]

Sounds awesome , good work , how many hours on the motor ?

And you've sold it ??

Top end rebuild and the rest of the motor is mint, checked it all out, basket etc has almost no sign of wear. Its not sold yet

[CHOPPA]

Finished!! Well pretty much, new tyres and carbon bits on the way. Cant wait to get it dirty...

[Stylo]

Looking good mate, nice job ;)

[Pornstar]

Whens ya commin up ta mine for a scoot then?