Ktm 250 Sx 2013
Forum Main Bike Builds Converting 2013 KTM 250 SX to 2017 KTM Plastics
Converting 2013 KTM 250 SX to 2017 KTM Plastics
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
3/13/2019 4:55 PM
Currently I am in the process of converting a 2013 KTM 250 SX to 2017 plastics
So far I have confirmed that I need the following 2017 components:
- Obviously, all the 2017 250 sx fenders/shrouds
- Gas Tank
- Subframe
- All air box components (plastics, rubber air boot, computer bracket, etc.)
- Seat
- And, all of the fasteners to secure the above components
Plastics found new on craigslist for $100
Gas tank on Ebay $175
Acerbis X-Seat on Ebay for $135
Subframe, airbox parts, and fasteners from Rocky Mountain MC for $365
That brings me to a current* total of $775. Still cheaper than a new bike so far, but I'm not done there...
At this point I know (neither of which are a surprise to me)
- The gas tank does not line up with the 2013 mounting points
- Both the upper and lower sub-frame mounting will require modification
The gas tank is sitting on the mounting stud and the sub frame is on the top mount. The air boot is contacting the shock. Obviously got some work to do, but I am excited to see how this turns out and I will update, with better photos, as I go.
Markee
Posts: 3351
Joined: 4/15/2013
Location: Suffolk, VA USA
3/13/2019 5:13 PM
Man I could save you some trouble. I have a stock 17 I'll sell ya!
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
3/13/2019 5:26 PM
Markee wrote:
Man I could save you some trouble. I have a stock 17 I'll sell ya!
Markee wrote:
Man I could save you some trouble. I have a stock 17 I'll sell ya!
She still has some life left in her, and I wanted a good project. What are the '17's going for?
bf884
Posts: 476
Joined: 1/11/2016
Location: Belle Chasse, LA USA
3/14/2019 4:52 AM
There was a thread here recently of a 2010 model that the conversion was done to. Went together nicely. Can't remeber if the tank fit or not.
#76
Posts: 620
Joined: 7/6/2012
Location: GBR
3/15/2019 11:40 AM
bf884 wrote:
There was a thread here recently of a 2010 model that the conversion was done to. Went together nicely. Can't remeber if the ...more
bf884 wrote:
There was a thread here recently of a 2010 model that the conversion was done to. Went together nicely. Can't remeber if the tank fit or not.
2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.
imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
3/16/2019 12:27 PM
Despite the updated frame, I'm finding many similarities to the 2010 to 2017 conversion on the forums.
I removed the top tank mounting stud to see if the tank would sit on the bottom tank mounts. Really committed now.
The tank sits on the front mounts ok, but the reliefs in the side of the 2017 tank do no line up with the frame supports on the 2013 frame.
It appears that the tank shrouds line up well with the radiator mounts.
Just as was done with the 2010 to 2017 conversion, I am going to heat the tank and see if I can mold some reliefs into it. Then, I can position the top tank mount and weld it on. With the tank positioned, I can then move onto positioning the sub-frame.
I have roughed in a design for the top sub frame bracket, but I will need to adjust the length. I am going to 3D print this part to make sure everything fits correctly before I hog it out of aluminum.
#76
Posts: 620
Joined: 7/6/2012
Location: GBR
3/17/2019 2:42 PM
Awesome!. Well done. 
2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.
imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
mitch199
Posts: 92
Joined: 11/20/2013
Location: AUS
3/18/2019 6:59 PM
Hell yeah man. How did the 3D printed subframe mount go?
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
3/19/2019 5:29 AM
mitch199 wrote:
Hell yeah man. How did the 3D printed subframe mount go?
mitch199 wrote:
Hell yeah man. How did the 3D printed subframe mount go?
I haven't printed it yet, probably this weekend. I bent up a little aluminum piece to hold the sub frame on while I confirm measurements. As you may see in the photo, the mounting point needs to be moved back and down which complicates it some. I do not want the joint between the sub frame and the adapter to pivot. I'm not sure this would add any degrees of freedoms because the bottom mounting points have offset heights, but I want to make sure that it doesn't transfer stress somewhere damaging the sub frame. Unfortunately I expect this to take a few iterations, but plastic is cheap.
#76
Posts: 620
Joined: 7/6/2012
Location: GBR
4/3/2019 1:06 PM
Any updates bro?...
2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.
imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
5/1/2019 6:50 AM
#76 wrote:
Any updates bro?...
#76 wrote:
Any updates bro?...
Had some things come up so I got derailed from this project for a bit, but I finally got to spend some time on it. Will be moving faster on it now that I'm wasting good riding weather.
What I have done since the last update:
- 3D printed some adapters for the top sub frame mount to hold it in place. These are obviously temporary, I will make a one piece bracket out of aluminum.
- The '13 exhaust did not line up well, and were beat anyways, so I decided to see if the '17 fit any better. The length is better, but the bend is off. I attempted to heat up the pipe where is connects to the silencer and bend it to get it to fit. After a few tries I could not get the bend it needed.
So, I cut it off.
- With that I was able to get the pipe to slide into the flange on the cylinder.
- made the bottom subframe brackets
- Turning the weld off of the pile to silencer flange will allow me to weld a new pipe from the flange to the rest of the pipe to get everything lined up. Looks to be 1.125" OD x .049" wall tubing
Coming soon:
- make some temporary tabs to hold the pipe in the position I want
- tack the bottom subframe brackets on the frame
- get the silencer as close to inline with the pipe as I can
- weld the pipe/silencer flange back on the pipe.
- to get the carb to fit up to the air box, I am going to space the carb back, by making a spacing to fit between the reed cage and the carb to reed boot.
5/20/2019 11:23 PM
How's the progress ? Gonna be doing mine this weeek/ next week. Do you have measurements for subframe and tank pin by chance? and did you and up heating tank?
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
5/23/2019 8:14 PM
Travis_West wrote:
How's the progress ? Gonna be doing mine this weeek/ next week. Do you have measurements for subframe and tank pin by chance? ...more
Travis_West wrote:
How's the progress ? Gonna be doing mine this weeek/ next week. Do you have measurements for subframe and tank pin by chance? and did you and up heating tank?
The best way is just to cut the pin off and set the tank on the bottom tank mounts, then mark the frame through the tank mounting hole. I think I ended up moving the pin back about 1".
The top of the subframe needs to be spaced back. I'll get on my other computer tomorrow to get you measurements for the top frame/subframe adapter. I made the bottom subframe brackets with everything else put together. Really just had to eyeball it and keep checking clearance between the airboot and the shock/spring. Hopefully this does not end up being an issue.
I did heat the tank some to get it to sit down on the frame a little better.
Next i'll be working on getting the carb to meet the new airbox, and getting all the exhaust to line up.
Good Luck, let me know if you figure out anything slick for carb to airboot.
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
6/19/2019 1:01 PM
CNC machined reed cage to carb boot adapter. A gasket was needed between the reed cage and the aluminum spacer. No major difference in tuning was noticed.
7/9/2019 5:26 PM
Hey there ! How do I get my hands on that spacer I'll pay whatever it's worth , text me whenever you see this message 780-504-0429
Rportillo
Posts: 1
Joined: 10/31/2019
Location: Frederick, MD USA
11/4/2019 9:54 PM
jbstaten wrote:
Last piece to go is the adapter for reed cage to carb boot. Currently I have a 3D printed spacer installed. The spacer has ...more
Is any way to get one of those subframe adapter?
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
11/5/2019 8:04 AM
jbstaten wrote:
Last piece to go is the adapter for reed cage to carb boot. Currently I have a 3D printed spacer installed. The spacer has ...more
Rportillo wrote:
Is any way to get one of those subframe adapter?
Rportillo wrote:
Is any way to get one of those subframe adapter?
Easiest way would be for you to make them.
11/18/2019 10:07 AM
Great progress, but by putting spacer after carb you decrease response, I made spacer for boot - carb, that did not affected throttle response. Good job mate.
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
11/18/2019 10:34 AM
Balzabubinas wrote:
Great progress, but by putting spacer after carb you decrease response, I made spacer for boot - carb, that did not affected ...more
Balzabubinas wrote:
Great progress, but by putting spacer after carb you decrease response, I made spacer for boot - carb, that did not affected throttle response. Good job mate.
I havent noticed any change in throttle response. Havent needed to re-jet either. I just went this route because it seemed the air boot didnt line up well in my case.
#76
Posts: 620
Joined: 7/6/2012
Location: GBR
11/18/2019 10:45 AM
Have you put many hours on her so far?.
2020.5 KTM Cairoli Factory Edition 5.7hrs
2019 Alta Redshift MXR - 0.9hrs!.
2020 KTM 250 SX 5hrs.
imoto34 wrote:
Look at all that torque. The kid on the lawnmower may have laughed so hard he shat his pants.
jbstaten
Posts: 15
Joined: 3/5/2019
Location: Ann Arbor, MI USA
11/19/2019 12:39 PM
#76 wrote:
Have you put many hours on her so far?.
#76 wrote:
Have you put many hours on her so far?.
Not too many. Maybe 8-10 hours.
YZed250
Posts: 702
Joined: 11/9/2014
Location: Costa Mesa, CA USA
11/22/2019 2:35 PM
Great job! More than the average person would attempt, but I'm sure you will have lots of ppl ordering spacers from you if you care to make more.
KTM250SX YZ125 YZ85 PW80 ZX6 FZX700
Forum Main Bike Builds Converting 2013 KTM 250 SX to 2017 KTM Plastics
Source: https://www.vitalmx.com/forums/Bike-Builds,46/Converting-2013-KTM-250-SX-to-2017-KTM-Plastics,1356172
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