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My 525 build from the US. Ol' Dog, New Tricks....

23K views 151 replies 28 participants last post by  crowwwwman 
#1 ·
Hello all, my name is Shawn. Some of you may already know me from SMJ. Just joined the forum for some research. Figured id keep you guys in the loop with my build. Excuses my American words/lingo. Iv built a hand full of supermotos but this is my first full size KTM supermoto. I own a Carbon Fiber company so expect some trick one off parts.:D

Iv been racing KTM minis for a while now. Took second in the Pro 85 class this year. The last race i raced my buddies 525 and fell in love. Started last on the grid (12th) in the unlimited class because i didnt race the qualifier. In one lap i took 2nd. Needless to say i had to pick one up.

KTM 85SX


Im working with a 2003 KTM 525 SX. I bought with SMR wheels, Beringer Front rotor and 4P caliper, and SME front and rear sliders. Other than that it is pretty stock.





So after i bought the bike i did some research and i came across (who you all know) Jon "Hugoagogo" KTM 540. I loved everything about it.

I ordered a 08 450 SXF Sub-Frame, Seat, Tank, Shrouds, 08 SMR Front Fender, and all new black plastics. As soon as i got the parts in i went to work. I knocked it out pretty quickly.





While i was drooling over Jons bike i found out about the Duke 2 wheels. Just so happen to search some local listings and found a front BBS wheel pretty cheap. Found out that was the easy part.... Its about near impossible to find a Duke 2 rear wheel in the US. Iv hopefully got KevINyork helping me out with one.



So here are my plans now. Iv got the frame, swing-arm, and sub-frame bare for powder coating. There going satin black. I have a LeoVince full Ti exhaust on the way. All black plastics on the way. A bunch of KTM billet parts on the way. Possibly a set of GDS triples. I already have a set of Carbon fiber fat bars. I have some Cycra SM Pro Bends with custom carbon fiber shields. Im sure im missing some parts/details. Ill keep you guys posted.

~Shawn
 
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#9 ·
Thanks for the warm welcome everyone, seems to be a solid group here. I went easy on the pics. Im a photo whore so ill be sure to post more.



I wish, most likely a set of 16mm. Im thinking because i have the 03 swing arm (25mm shorter) that it may work out better than a new longer swing-arm for handling.

Loving it mate :D, nice pics, did the 03 frame need much welding / fabrication??
Keep us posted with more pics etc.

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It was pretty easy. Hugo's bike was the only reference i had and it appeared* to be the newer 05 style frame. My 03 frame was a walk in the park if you know basic weld/fabrication.

More woke today and parts today. Update later.

~Shawn
 
#5 ·
Loving it mate :D, nice pics, did the 03 frame need much welding / fabrication??
Keep us posted with more pics etc.

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#7 ·
So after i bought the bike i did some research and i came across (who you all know) Jon "Hugoagogo" KTM 540. I loved everything about it.
Good bike that, frame was done by Hugo's mate PecGaz on here, frame now in my garage :D:D.
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#8 ·
03 is easier to convert cos it has the tubular upper subframe support. Thats the same model year I started messing about with back in 2008... Gaz came and took a look...... and the rest is history ;) I still have not got round to finishing my own conversion :D
 
#15 ·
Thats nothing. I think im opening a can of worms....i love me some minis and some carbon fiber.

88 YSR50 72RR
Before,


After, This is about 80% one off. Wheels, body, frame, on and on....






Diffrent mini bike. Custom trellis frame, 450 motor....





88 ZB50 Reso.
Before


After


87 YSR 50 (XR200 motor)





Enjoy....:scooter:

~Shawn
 
#20 ·
that 85 ktm is fucking lovely can i please buy it lol. your already my newest bestest friend on here. ive had a few gag bikes over the years mainly nsr and ysr's. a bit lesser specced then yours though lol
 
#25 ·
Alright back to the topic at hand. Id could be here for days just talking about one of my minis.

Some new parts.
Driven Carbon Fiber Fat bars.
Cycra SM Pro Bends

I made some carbon guards for them.


My new Brembo. I had the stock SX master on the bike. That wont do....


My graves Catch can. Im hot a huge fan of the OEM SMR catch can. They seem to leek or crack over time.


Still waiting on some parts to get in, but i hope to have the frame/swing-arm/sub-frame back from powder coating my mid week. Ill be putting this thing back together soon. Hopefully ill have my rear wheel situated in the next few days (thanks again Kevin). Im going to powder coat the wheels like the new KTM125 SB concept. They used the same BBS/Brembo wheels. Basically they are half white and orange. If your not sure about the looks.... hold tight and trust me. More soon....

~Shawn
 
#29 ·
Thanks headster.

Well frame/swing-arm/sub-frame and a few bits are off to powder coating. They all went satin black. Should be ready for pick up in a day or two. I also go my all black plastics in. Most of my other goodies and performance parts should be rolling in any day now. Just waiting on my wheel/number plate situation ( "Cough Cough" Kevin "Cough Cough" :D ). As always more carbon and more to come... Hoping to have this thing ready to race in a week or two.

~Shawn
 
#32 ·
best thread on here at the mo. also i hear kev likes whispering sweet nuffinks in hes ear:eek: if you feel the need to repay then favour lol :D
 
#37 ·
Thanks^

I received some more parts today.

Man i made out like a bandit! So heres the short of it. I ordered a Full system Ti LeoVince discontinued exhaust form LeoVince for $250USD. I waited and waited and nothing. So i called them up and they couldn't find it or any shipment info. (I think they sold something they didn't have in stock) So they ended up giving me there newest exhaust thats Full Ti (old one was partly Ti) and had carbon end cap and heat shield. So i got a $1,200 for $250! That will never happen again! Just found out that the 03 exhaust head flange is different from the 04 (i got an 04+ exhaust) I thought that the sub frame would have been the exhaust difference..... now i have to order one.


I also got an R&D slider.


Lastly my 08 KTM black plastics.



The parts should start rolling in..... more soon....


~Shawn
 
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