View Poll Results: Big bore kits, who has used what, any comments post em

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  • Factory 540 kit

    9 20.93%

  • Factory 100mm cylinder setup

    3 6.98%

  • Thumper 540

    5 11.63%

  • Thumper 570

    8 18.60%

  • HT racing 543

    0 0%

  • other specialist builder

    3 6.98%

  • stock is best……...

    15 34.88%
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Results 1 to 14 of 14
  1. 02-17-2012 11:42 PM #1
    kiwi-craig [OP]
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    Big bore kits, who's using what ?

    okay, relates to the XC / RFS engine

    factory 540

    factory 100mm cylinder setup

    Aftermarket kit

    Thumper racing 540 kit - 97mm

    Thumper racing "570" kit - 99mm

    HT racing 543 - 98mm ?

    other kit supplier, let us know the details. there are several 100mm setup around, plus the 102 / 104 mm units from europe.

    any other comments / experiences, post em up.
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / DJH cam chain tensioner
    Next round of mods: oil cooler........ the NEW TOP DOG

    KTM 560 XC: 560 sx style light weight 72mm crank by cut 7, balanced, with DJH pressure feed drive side main bearing setup, DJH stator main bearing oiler, light weight SXF flywheel, TT SXF stator - Swartfager billet stator adapter, DJH cam chain tensioner , Thumper racing 99mm CP with ceramic coating, DJH plus 1 ported head / Travis STG 5 billet cam, 44mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, Wp's front and Rear with Kiwi ZPS suspension, Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics.
    Next round of mods: PB oil cooler........

    gotta stop spending $$$ on these KTM's........

    LTR 450, My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / Yoshi cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head...... the clark kent of the ATV trio ! 150hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ Vets (40+) North Island MX champ 08 & 09
    NZ Vets (40+) TT champ 06, 08 & 09
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09 & 11

    hope to get a good season in for 2012.........
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  2. 02-18-2012 12:06 AM #2
    flooringit
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    Also have a 102mm set up. Will be here next week
    637
    8/10 cam or stage 6 depends on who you but it from
    plus 1 head
    slingshot lock up
    fci intake, 43.5 carb
    plus 8 swingarm
    ktmbill exhaust
    JJ&a play axle
    high flow water pump
    direct drive spindle mounts (thanks nmachine)


    http://s1107.photobucket.com/albums/...rrent=drag.jpg
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  3. 02-18-2012 05:04 AM #3
    spudnik
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    I have a 100 mm factory and a 99 thumper, only allowed 1 vote so it went to 100mm
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  4. 02-18-2012 07:16 AM #4
    5.0fox
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    I got the thumper racing 540 now but i just bought a thumper 570 to step it up a notch
    New dune build in progress: Thumper racing 570 with 13.5:1 CP piston, DJH big valve head with kibblewhite valves and springs, DJH 44mm fcr, Thumper racing stage 6 cam, Slingshot clutch lockout with EBC springs,EHS airbox vent, FCI intake and HMF exhaust.

    Looking for a +4 swingarm and 22" 8 paddle sls haulers
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  5. 02-18-2012 11:53 AM #5
    polaris bob
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    I'm running a thumper 570 kit.
    2003 Polaris Predator / 2004 KTM 525 exc 6 speed motor.

    570 Thumper Racing kit w/ 12.5 - 1 CP piston.
    Head ported by Thumper Racing w/ new intake seats done by Pro-1 racing.
    Stage 5 cam ( Custom design by Thumper Racing )
    AC bearing mod.
    Oil system mod by DJH.
    KW valves ( stock size )
    * #100 CDI dirt bike CDI.
    42 mm FCR carb by Walt/ Fast64ranchero. ( SX carb = No TPS )
    Trail Tech -10 oz flywheel. ( Stock is 30 oz/ trail tech = 21 ozs )
    Mino water pump. Full flow set up, no T-stat.
    PB Oil cooler.
    Custom modded intake. Uni filter/ D2 moto adapter on a modded Predator intake tube.
    KTM Bill modded, CT racing full exhaust system.
    Tusk Clutch kit.
    Honda thumb throttle.
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  6. 02-18-2012 02:30 PM #6
    ls1fury
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    Trying to finish up the Thumper 570 Kit today if everything goes smooth
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  7. 02-19-2012 08:17 AM #7
    kamyk
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    How many hours did you guys put on you builds ? Just pondering whether its reliable to make it 570 or stay with 540cc. I wouldn't mind to run thumper 570cc for the 12h race of PDV in France ...

    www.ATVriders.pl

    #85
    Sponsors: Lonestars, Fourwerx, KTM, Precision, Quady Srem Racing Team, PEP suspension

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  8. 02-20-2012 01:39 AM #8
    spudnik
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    My factory 100mm was torn down by Dave Hopkins after 130 hrs and he said the rings were still good and it now has 160 hrs with no issues. this is a 13-1 compression motor. The 99mm has very little milage so I can,t say
    Tom
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  9. 02-20-2012 01:51 AM #9
    tparsley
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    I have a 104mm x 78mm with some other goodies Makes 73 hp 52 lbs tq and a 102x78 haven't dynoed yet but it runs very strong , in theprocess of doing a 99mm stock stroke as a back up dunner .
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  10. 02-20-2012 06:31 AM #10
    kiwi-craig [OP]
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    i like it, three built to the eyeballs BB's…… LOL
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / DJH cam chain tensioner
    Next round of mods: oil cooler........ the NEW TOP DOG

    KTM 560 XC: 560 sx style light weight 72mm crank by cut 7, balanced, with DJH pressure feed drive side main bearing setup, DJH stator main bearing oiler, light weight SXF flywheel, TT SXF stator - Swartfager billet stator adapter, DJH cam chain tensioner , Thumper racing 99mm CP with ceramic coating, DJH plus 1 ported head / Travis STG 5 billet cam, 44mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, Wp's front and Rear with Kiwi ZPS suspension, Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics.
    Next round of mods: PB oil cooler........

    gotta stop spending $$$ on these KTM's........

    LTR 450, My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / Yoshi cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head...... the clark kent of the ATV trio ! 150hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ Vets (40+) North Island MX champ 08 & 09
    NZ Vets (40+) TT champ 06, 08 & 09
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09 & 11

    hope to get a good season in for 2012.........
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  11. 02-21-2012 01:39 AM #11
    spudnik
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    Where did you get your cylinders from, the 104mm is getting 10 hp over my 100mm with the same stroke.
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  12. 02-21-2012 02:38 AM #12
    kiwi-craig [OP]
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    104mm, one source is Josef in Germany.

    ::: FRAUENSCHUH-Tuning :::Racing EXC-SX

    I think travis @ thumper is also experimenting with one offs.
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / DJH cam chain tensioner
    Next round of mods: oil cooler........ the NEW TOP DOG

    KTM 560 XC: 560 sx style light weight 72mm crank by cut 7, balanced, with DJH pressure feed drive side main bearing setup, DJH stator main bearing oiler, light weight SXF flywheel, TT SXF stator - Swartfager billet stator adapter, DJH cam chain tensioner , Thumper racing 99mm CP with ceramic coating, DJH plus 1 ported head / Travis STG 5 billet cam, 44mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, Wp's front and Rear with Kiwi ZPS suspension, Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics.
    Next round of mods: PB oil cooler........

    gotta stop spending $$$ on these KTM's........

    LTR 450, My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / Yoshi cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head...... the clark kent of the ATV trio ! 150hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ Vets (40+) North Island MX champ 08 & 09
    NZ Vets (40+) TT champ 06, 08 & 09
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09 & 11

    hope to get a good season in for 2012.........
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  13. 02-21-2012 02:41 AM #13
    flooringit
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    spudnik Travis has been doing 104mm for awhile. and 10 hp more then 100 could be different cams and porting really should only be 4hp difference, If your getting 62 with your 100mm thats pretty good. im gettig 64 with a 99mm. but my cam is huge and porting is great, good luck
    637
    8/10 cam or stage 6 depends on who you but it from
    plus 1 head
    slingshot lock up
    fci intake, 43.5 carb
    plus 8 swingarm
    ktmbill exhaust
    JJ&a play axle
    high flow water pump
    direct drive spindle mounts (thanks nmachine)


    http://s1107.photobucket.com/albums/...rrent=drag.jpg
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  14. 02-22-2012 03:39 AM #14
    tparsley
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    Flooringit is right Travis , and it takes more than cc's to get hp . Carb , valves , cams ,exhaust and great porting !! The rfs engine make low 60's easy but after that it a litttle harder to come by . I've seen a 540 make 66hp on
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