2001 Ktm 380 swap
- Thread starter Steveforg
- Start date
been awhile since ive been on here but I always checkout the mod/swap forums. my old man is the guy that swapped the 03 sx250 ktm motor into his blaster successfully!! an don't underestimate when I say its ALOT of work, we found theres a few extra probs with the 300cc motor as we have one of those aswell. I have built a dt200 blaster (my display pic) and I have a modded factory aircooled blaster, also have a slightly modded banshee!!
my advise DONT DO IT!! the sx250 blaster is a savage!! very peppy but hard to control, vibrates like crazy an the gear ratios don't favor a quad. the dt200 swap with powervalve is a very sweet setup!!! not as powerful as the 250 but extreamly smooth power, an NO I would say the 250/300/380 in a blaster would not overtake a slightly modded banshee, its just to much power for such a small quad, don't get me wrong it would be close to the performance of a banshee but all in all the banshee is a much much better design all around an even in drags it would have a time passing a shee.
if you are going to do it!!! POWER TO YA take lots of pics an let us know how ur making out! check out BEST on here an look up his build its very well documented an you will learn a few things by taking a read!!
my advise DONT DO IT!! the sx250 blaster is a savage!! very peppy but hard to control, vibrates like crazy an the gear ratios don't favor a quad. the dt200 swap with powervalve is a very sweet setup!!! not as powerful as the 250 but extreamly smooth power, an NO I would say the 250/300/380 in a blaster would not overtake a slightly modded banshee, its just to much power for such a small quad, don't get me wrong it would be close to the performance of a banshee but all in all the banshee is a much much better design all around an even in drags it would have a time passing a shee.
if you are going to do it!!! POWER TO YA take lots of pics an let us know how ur making out! check out BEST on here an look up his build its very well documented an you will learn a few things by taking a read!!
The picture below is a Blaster frame with a 2003 KTM 250SX motor setting in it.
The motor on the floor is a roughly same vintage KTM380 EXC.
Notice the slight difference of the cylinder angle?
This picture below might show it better.
In 2003 KTM "straightened" up the cylinder to better compact the mass and improve the Polar Moment of Inertia to get the bikes to turn in quicker. I could not get the older 250/300/380 to fit without cutting the Blaster frame. You need a 2003sx/2004exc or newer motor for best fit.
About cutting and welding the frame? It is chrome moly, does not weld well.
The 380 and 250/300 both evolved from a mid-1990s motor but are quite different. Very few common parts whereas the 250-300 can be very interchangeable. All really feel like they make about the same power (about 50hp), but just at lower rpm with the larger displacements. The 2003 is one of the hottest year engines, although some say it only makes 45-47hp. In a Blaster traction and wheelies are your problem. It will go through all 5 gears as fast as you can click them.
2003 KTM250SX, 2002 KTM380EXC. Note the cylinder angle, longer kick arm, different covers.
This side shows the lightened flywheel and more compact design of the 2003 250SX.
It is almost 10 lbs lighter and a real screamer.
Here is a trial fit of the earlier 2002 250/300:
I could not get the motor to tip forward enough to get the kickstarter to clear the frame. See how high the front of the motor sits? The paper mounts are mock-ups for fabbing metal. This motor was tried but not installed.
You can see below where the 2003SX kickstarter BARELY cleaed the frame.
I flattened the frame to gain clearance.
Here is the KTM nicely placed in the KTM, many don't even notice the 3X power swap.
It is brutally powerful, will wheelie at any speed even with a +2 swingarm.
An interesting feature of the 1996-2002 KTMs is the resonant chamber on the exhaust. These are both KTM 300 cylinders but one features a resonant chamber for slightly more mid-range torque.
Here is what it looks like inside. (Bad photo, sorry) Basically a Helmholtz resonant chamber.
This was not an easy swap and has several issues.
1) The gearbox is too close ratio even on the EXC models
2) WAYYY more power than a stock Blaster chassis, brakes and suspension are designed for.
3) Pipe is critical and you will have to cut and weld to fit. You have to get it right.
4) Banshees and 450F machines will hate you. They call it a "kid's toy and refuse to race.
The 2003 250SX struggles to get all its power to the ground, I have a 300 cylinder for it but have never felt the need for it. Ample power, more than you can use without major suspension and chassis mods.
Steve
The motor on the floor is a roughly same vintage KTM380 EXC.
Notice the slight difference of the cylinder angle?
This picture below might show it better.
In 2003 KTM "straightened" up the cylinder to better compact the mass and improve the Polar Moment of Inertia to get the bikes to turn in quicker. I could not get the older 250/300/380 to fit without cutting the Blaster frame. You need a 2003sx/2004exc or newer motor for best fit.
About cutting and welding the frame? It is chrome moly, does not weld well.
The 380 and 250/300 both evolved from a mid-1990s motor but are quite different. Very few common parts whereas the 250-300 can be very interchangeable. All really feel like they make about the same power (about 50hp), but just at lower rpm with the larger displacements. The 2003 is one of the hottest year engines, although some say it only makes 45-47hp. In a Blaster traction and wheelies are your problem. It will go through all 5 gears as fast as you can click them.
2003 KTM250SX, 2002 KTM380EXC. Note the cylinder angle, longer kick arm, different covers.
This side shows the lightened flywheel and more compact design of the 2003 250SX.
It is almost 10 lbs lighter and a real screamer.
Here is a trial fit of the earlier 2002 250/300:
I could not get the motor to tip forward enough to get the kickstarter to clear the frame. See how high the front of the motor sits? The paper mounts are mock-ups for fabbing metal. This motor was tried but not installed.
You can see below where the 2003SX kickstarter BARELY cleaed the frame.
I flattened the frame to gain clearance.
Here is the KTM nicely placed in the KTM, many don't even notice the 3X power swap.
It is brutally powerful, will wheelie at any speed even with a +2 swingarm.
An interesting feature of the 1996-2002 KTMs is the resonant chamber on the exhaust. These are both KTM 300 cylinders but one features a resonant chamber for slightly more mid-range torque.
Here is what it looks like inside. (Bad photo, sorry) Basically a Helmholtz resonant chamber.
This was not an easy swap and has several issues.
1) The gearbox is too close ratio even on the EXC models
2) WAYYY more power than a stock Blaster chassis, brakes and suspension are designed for.
3) Pipe is critical and you will have to cut and weld to fit. You have to get it right.
4) Banshees and 450F machines will hate you. They call it a "kid's toy and refuse to race.
The 2003 250SX struggles to get all its power to the ground, I have a 300 cylinder for it but have never felt the need for it. Ample power, more than you can use without major suspension and chassis mods.
Steve
