It wasn’t a pretty sight. Every part of the former MX bike was laid before us. We had already received the motor and forks back from Pro-circuit who rebuilt the motor, evidenced by old top end that was still in good condition. Additionally, they installed the Barnett clutch kit and Moto Tassinari’s vForce3 that were sent. The forks and shock came a day later, reworked by Pro-Circuit and prominently displayed their trademark logo.
Pro-Circuit also provided us with a pipe and silencer. The pipe is their distinctive Works Exhaust Pipe with its hand welded, styling industrial finish complete with pounded seams. The R304 Stainless Silencer they sent along is used by practically every Pro-Circuit equipped racer out there. Its housing is made of lightweight aluminum with a brushed finish that nicely hides any nicks. For some reason we had to muscle the silencer a bit to align the mounting bracket. We also had a bit of an issue fitting the all bodywork, which implied to us that our used bike had flipped in its previous life and came out worse for wear with a slightly tweaked subframe.
The 2004 KTM shipped with silver powder-coated components. I have both a general aversion to silver frames and wanted to give the bike a unique feel. So we had Everlast Custom Powdercoating powder-coat the frame, subframe, swingarm, and footpegs in semi-gloss black which were all carefully wrapped in cardboard boxes. Only after having this done we learned that the 2007 KTMs were going to ship with a black main frame. So much for being unique in the frame department.
The rest of the bike lay in boxes and zip-lock bags labeled with their contents. By simply grouping the various components in separate bags and marking them, we were able to quickly reassemble components without issue and in a matter of hours.
In every mini club we have come across the 65 motard class allows for aftermarket brakes. From the factory, the KTMs have been known to have good brakes and up until 2004 they shipped with Brembo master cylinders. The 2004 KTM uses an 8mm steel braided line which is common on high-end mountain bikes. We had contacted GP Tech about using one of their thumb brakes to actuate the rear brake. A thumb driven rear brake allows a motard rider to ride foot out into right hand corners, which is a significant advantage over the standard foot pedal. The thumb brake is also commonly used on stunt bikes where the rider might take their feet off the pegs. Unfortunately we weren’t able to bolt up the thumb brake to the 2004 braking system. The reason? That crazy 8mm line that KTM switched to. Bikes using the standard 10mm line would have no such complications. We were sad, but will give the GP Tech thumb brake a try on another bike soon.
We weren’t completely bummed out though because Galfer recently started making wave rotors and pads for the KTM65SX. And it just so happened that they were interested in getting some feedback. The rotors are a noticeable upgrade from the stockers. Not only do they have a good feel to them, they had less sprung weight allowing for quicker transitions. They also cooled faster and when combined with Galfer’s pads, didn’t fade even when run long and hard. They bolted right up with zero issues. The Galfer parts were definitely a worthwhile upgrade to stock system.
We broke with motard convention and went with road racing clip-ons instead of the traditional MX handle bars. We initially intended to go with the MX bars, but after seeing Royce McLean’s YZ85 running clip-ons we decided to try it out. We called up Graves Motorsports and caught them on a good day. They agreed to send us a set of 45mm clip-ons commonly found on road racing bikes. In this particular instance, using a KTM as the basis for this project was a big advantage. The KTM not only runs inverted front forks that allow the use of the common sized 45mm sized clip-ons, it also has a billet triple tree. While it may not mean much to MX folks, it meant that the entire handle bar perch could simply be unbolted from the top of the tree. This allowed us to drop the front end by simply dropping them in the triple tree. We were able to lower the front end of the bike without opening the front forks. For folks converting an RM, for example, wouldn’t be able to run clip-ons without some fabrication. And if they stayed with MX bars, the top of the fork tubes would hit the bar limiting the ability to drop the front end. Their only option is to open the forks and hack away. The KTM avoids all of that. Its not all roses with the KTM, as you will read, as it has its own road blocks. But it sure did look good when we put those clip-ons on the forks.
We set the angle on the clip-ons to mimic the angle used on a NSR50. We then mounted up the ╜ waffle Soft Grips provided by Renthal. While the Renthal grip glue was an adventure, it worked well and we haven’t seen any rotation or slipping of the grips since installation. My only advice it to make sure you put enough glue on that it slides easily, and do the work installation quick, because the glue dries fast.
ASV Inventions sent us a set of their unbreakable levers in red. They were a breeze to install and impressed us so much, that we ordered up a set for the team’s NSR50 as well. They are light, yet built not to break through the patented folding design. Bend them backwards and they spring back into place. As anyone that has dropped a bike knows, the first thing to snap in the lever. I am not excited to say that we tested the levers, but we did. The bike has since been down a few times and the ASV levers came through 100% functional with only minor scuffs to the hardware itself. While not cheap, the levers are cheap insurance when you have a junior rider who tip-toes a bike and may drop it on occasion.
In the bike’s previous life it had been around the block a time or two and so had its drive train. We’ve used Renthal products over the years and have always found them to be top notch so it was a no-brainer to contact them. We received a selection of their UltraLite chainwheels and a R-1 420 chain. In a matter of minutes we installed the 14/46t gearing combination commonly used by flat trackers.
With everything in place we went about the business of tightening up the rear axle. Of course it is only after you have everything together and ready to go that the laws of physics creeps its ugly head. There was only had a half inch of space between the rear tire and the cross brace. To make matters worse, that was without the mud guard installed and with the axle at the end of the adjustment. We had no room. If anything had to be adjusted (gearing, chain tension, etc), the tire would rub the cross brace on the swingarm. By this time I’m sure you’re probably thinking I’m a retard because of course you check clearances first. Well, I did one better. I asked someone that did the same rear tire set-up on their dirt tracker. Using the same size wheel, same tireaexcept that it turns out that he didn’t use the same exact tire. He used a generation before. It was the same 120/80R12 size, same brand, but we had the newest tire, Bridgestone’s BT601SS.
To be clear we choose the tire specifically because it was Bridgestone’s new tire. We also choose it because it is a true MiniGP tire, not a scooter tire. There are other tires on the market, but we wanted to run this tire. And while this was a unique tire issue because of the design of the KTM’s swingarm, we didn’t have any clearance issues on the front. KX motards for example have tire clearance issues on the front as there isn’t every much room between the front forks which require even the narrower scooter tires to be trimmed to fit between the spindly forks. Imagine the magnitude of the problem if they tried to shoehorn a meaty MiniGP tire in there. Eash.
After lots of afterthought and some more conversations on the KTMTalk.com forum, we went about the task of lengthening the swingarm. There were other options of course. One of the most attractive was a custom swingarm. Aftermarket swingarms could have been easily modified by the designer to accommodate our needs, but it would have cost $450 and taken six weeks. Instead we visited our local welder with explicit instructions. It took two days and $200. The only stinker is that the swingarm had already been powdercoated, but at least the industrial look the welding resulted in matched the factory finish on the Pro Circuit pipe. After both the swingarm and rear brake mount were extended to accommodate the meaty Bridgestone, we finished the final assembly.
Since this was a MiniGPX project bike, we choose to run it in our team’s colors. That meant it would not be seen in the traditional KTM orange. We went with all black Polisport bodywork and Mick Peterson at SpeedGraffix created a custom sticker set for the bike. When we first saw was Mick had pulled together we were blown away. The full body sticker kit was top notch across the board. While the black bike was nice, it was only when the SpeedGraffix was applied that it really looked the part.
After some appreciating how sweet Mick’s work looked, we took it off the bike for fear of rashing it up on the first outing. It went back in the wrapper, and would remain there until we had shaken the bike down. Dressed back in orange, all that was left to do was break in the motor and take it for a spin.
a continued in Part 4 a
How to reach these guys
ASV
~http://www.asvinventions.com~
Barnett Tool & Engineering
~http://www.barnettclutches.com~
Bridgestone
Performance Tire Service Co.
+1 (317) 890-4500
Buchanan Spoke and Rim
~http://www.buchananspokes.com~
Everlast Custom Powdercoating
+1 (360) 225-6084
Galfer Braking
~http://www.galferusa.com~
GP Tech
~http://www.gptechllc.com~
Graves Motorsports
~http://www.gravesport.com~
KTM North America
~http://www.ktm.com~
Moto Tassinari vForce3
~http://www.mototassinari.com~
Pro Caliber Motorsports
~http://www.procaliber.com~
Pro-Circuit
~http://www.procircuit.com~
Pro-Wheel Racing Wheels
~http://www.prowheelracing.com~
Rain City Powersports
+1 (360) 574-2755
Renthal
~http://www.renthal.com~
SpeedGraffix
~http://www.speedgraffix.com~