KTM motard conversion using RGV rims - Please help!!

[ktm450]

Hi all,

I own a 05 KTM 450exc and have recently purchased a pair of RGV rims to set up for motard. I would really appreciate hearing from anyone who has tackled this conversion.

What discs did you run?
Did you use the KTM hard equipment caliper extension?
Does 320mm disc need spacing out to prevent caliper fouling rim?
Does the drive sprocket need spacing out to line up with rear sprocket?
How did you set up the front axle (change bearings or machine up reducing bushes for fork clamps)?
Spacer sizes?
Any other machining?

Please help!!
Thanks

[Muzzard]

G'Day Mate.
You have some work before you no doubt.
Also suggest there may also be a bit of machining.

Seriously,
Unless the wheels owe you an arm & leg,
offload them through EBay and buy yourself one of the many cheaper KTM specific sets that are coming up there regularly.
You will usually score all the right stuff for the conversion and at about what it will cost you to do your conversion plus buy the donor rims.
My 2 cents worth..

Backmarker (Mitch) may be able to assist you as there are a couple of earlier KTM's in the WA scene with mags inserted,
Shoot him a PM through here mate
Good Luck and someone will come here with the right info for you if you still wanna go the mag route too.
Cheers ;)

[yobgow]

I have a few customers with RGV rims on 525s. You will need to space the wheels with some custom spacers and use a flat 320mm disk (ie, no dish), plus all the other stuff. Its no too hard, but..........
unless you know what your doing, I would suggest you take it to some who does.

[SMC690]

I have a hardly used 320mm stock disc off an SMC if you want to try that bit as a starting point.
If it fit's you can make me a reasonable offer on it, if it doesn't you can give it back.

Cheers,
Juz.

[yobgow]

Count how many bolt holes the RGV rim has to mount disk and compare before anything!

[ktm450]

Thanks for the replies guys,
I have no problems doing the machine work as I am a Fitter & Turner, I was just hoping for a little advice on any tricks or difficulties before I rip into it. I don't think the SMC disc will fit as the RGV hub is very different.
Does anyone know of anyone who laser cuts new discs, the front is a 320mm disc on a 64mm boss, 5x 10mm holes on a 87mm PCD.
Thanks

[Sibbo]

You might try awesome discs in Ringwood, (03) 9879 7755. Small little shop that does good prices on disks.

[tambi]

Got my disc made by www.Aussiediscs.com.au

http://www.vsmr.net/modules.php?name=Forums&file=viewtopic&t=1334&postdays=0&postorder=asc&highlight=disc&start=0

[WOOLO]

Hi 450, I did the mag wheel conversion on a dr 650 and made all the spacers and stuff myself,fitter by trade also.I went for oversize wheel bearings on the I.D and made spacers with a spigot on each end and pressed bearings on and then into wheel.With the rear wheel I measured the distance from the swingarm to the disc and to the sprocket on the original rim and spaced the disc and sprocket on the mag wheel to keep these measurements the same as the original wheel.I made my own discs from 350 grade plate lathed and drilled to size then surface ground flat.Made an alloy carrier for the front and re-machined the rear wheel spigot to get the correct offset.Painted the discs with hi temp brake paint and let the pads cut off what they didnt want.Discs have done about 10,000kms and are spot on and pull up from high speed easily.

[ktm450]

Thanks for the info guys,
I'll try both the brake shops you have mentioned and let you know how I go.

[Muzzard]

I didnt realise you were a fitter 450,
In that case go the route WOOLO suggests and make integral alloy spacers that are also the inner bearing support as well as axle retainer/spacers...
You can use steel obviously.
Set up the wheels dummy and measure away ;)
Grab a hunk of rod and start turning...

[ktm450]

Hi guys,
Awesome Disks could supply me with a 320mm wave disc with approx 8mm offset and a 220mm wave rear to suit the RGV rims for $450. Aussie Disks could supply me with a 320mm flat wave disc for $300 and 220mm rear for $185. Both guys were very helpful and dont have a problem making discs for any conversion.

I may have run into another snag though. I have recently seen a RGV set-up on a 01 KTM 520, but I think my rims may be slightly wider, I'm not sure, my sprocket will sit out approx 92mm from the centre line of the rim, where the standard KTM rim is approx 83mm.
I'm thinking I''l have to run the sprocket on the inside of the sprocket carrier as 9mm offset is a little large. (This would run the wheel dead centre of the swingarm)
My rim is 135mm wide which I guess is close enough to a 5" rim. I didn't measure the 520s rim but it is running the sprocket in the correct location.
It won't really be an issue but I'll have to watch the clearance between the chain and tyre.
Does anyone know if there were different width 17" RGV rims??

[megahead]

is it definitly off a rgv ?
could be off any 250/400 from that vintage
i dont know off hand if rgv's had differant size wheels
but they did have a few differant swingarm designs , or maybe you can just machine down the carrier to move the offset in ?

[ktm450]

Fairly sure they are RGV, but could be off something else. I used to own a RGV years ago they look exactly the same but cant be 100% sure.
Not enough meat to machine off the outside of the carrier. Could machine the cush drive webbing, inside of carrier and cut the rubbers, but it is much easier to run the sprocket on the inside.