Posts
1393
Joined
5/9/2013
Location
Hyllykallio
FI
Edited Date/Time
12/17/2020 10:21pm
I have started to rebuild my 150SX after connecting rod broke last fall (You can read it from here).
I had previously removed Trax shock and SXS forks from the bike and put them on my 250SX and after that it has been sitting in my garage floor looking like this.
I managed to find used engine cases for a good price. They are previous generation cases with no place for starter motor but I don't need that anyway. I also got older style ignition cover to go along with the cases
Broken cylinder was repaired and ported by KJ
Complete Wrench Rabbit kit courtesy by Hot Rods to rebuild the bottom end
I matched the cylinder with the cases. There was really bad overhang on the rear transfer ports. I read on the online that it is there because same cases where used for 200SX and best way to fix the overhang is to fill the cap with epoxy. I decided to go for it. This is the the first time I'm trying something like this and I hope epoxy will stay on the cases
Before epoxy filling:
And after:
I had previously removed Trax shock and SXS forks from the bike and put them on my 250SX and after that it has been sitting in my garage floor looking like this.
I managed to find used engine cases for a good price. They are previous generation cases with no place for starter motor but I don't need that anyway. I also got older style ignition cover to go along with the cases
Broken cylinder was repaired and ported by KJ
Complete Wrench Rabbit kit courtesy by Hot Rods to rebuild the bottom end
I matched the cylinder with the cases. There was really bad overhang on the rear transfer ports. I read on the online that it is there because same cases where used for 200SX and best way to fix the overhang is to fill the cap with epoxy. I decided to go for it. This is the the first time I'm trying something like this and I hope epoxy will stay on the cases
Before epoxy filling:
And after:
All the bolt holes covered with old bolts the frame is ready for sand blasting
I made 3D model of skid plate mounting tabs and had them laser cut from a 3 mm thick steel plate
The frame of the bike was sand blasted and skid plate mounting tabs a where added to the frame along with some extra welds on critical areas on the frame
After that the frame was powder coated with orange color and layer of clear coat
I did self made skid plate from a 6 mm thick ABS plastic sheet
The Shop
Shifting mechanism parts in ultrasonic cleaner
Clutch assembled with new clutch plates
Bottom end completed
Cleaned power valve parts ready for assembly
Power valve assembled
Top end completed with brand new Vertex piston
Notice Kokusan 2K-3 stator and heavier flywheel from KTM 125 EXC
Because I have used older style engine cases without place for a starter motor I had to use older style magnesium ignition cover which I think is better design than the new plastic ones
Engine ready to go back in the frame
I had to get Samco coolant T-piece to replace the original one which was destroyed while I was removing it
The engine and the frame united again
Corner support pieces ready for welding
Support piece welding completed
Radiators mounted back to frame
If u look carefully the last picture you can see that corner supports in left radiator are in different position than the ones in right side radiator. Welder made that that mistake and I was bit bummed about that. I also learnt my lesson and will do symmetrical corner support pieces next time...
I applied some high temperature masking tape on top of the VIN number before I took the frame for sand blasting. I instructed that area where the tape was should not be blasted. The guy who did actual blasting did not apparently get the message and destroyed the VIN number in the process.
I tried to punch new VIN number back on the fame, but it turned out impossible task because KTM VIN is located on round head tube surface and I couldn't get it stamped with my tools. I think I'll just have to write VIN number to the frame with permanent marker pen
Carb went trough ultrasonic washer
Then it was time to rebuild suspension. I rebuilt my SXS front forks myself
I also got new CNC machined footpegs from Ebay
Linkage and swingarm bearings where in good shape so I ended up just cleaning and greasing them
Rear shock and linkage mounted.
Pit Row
Subframe was welded on places where plastic edges where starting wore through aluminum. After I smoothed out the welds it look almost like new
I cleaned surface rust from my BUD/HGS pipe
It's starting to look like a motocross bike again (ignore my messy garage)
https://youtu.be/VgHGK9zZIqc
Brake piston and pads were in really bad shape and needed to be replaced
Brake pedal got new replacement tip
Rear brake mounted back on the bike with Fasst Company brake return spring kit
Sneak peek of the graphics.
I re-branded the bike to 150 SXS like KTM factory bikes back in early 2000's
Post a reply to: 2013 KTM 150 "SXS" Build (finished pics)