BRC 5100CC CONVERSION KIT TO SUIT KTM 07-16 250/300

This 510 cc conversion kit is intended for KTM 250 and 300 EXC, XC and XC-W models from 2007 to 2016. It is designed to convert a compatible donor engine into a 510 cc two-stroke configuration by reusing major original engine components, so it is not supplied as a complete engine.

Features

• Converts a compatible KTM 250/300 donor engine to 510 cc


• Uses a pneumatic power-valve system for smooth, linear power delivery


• Accepts the donor 5-speed or 6-speed transmission


• Compatible with kick-start and electric start systems


• Fitted with a decompression button to assist starting


• Incorporates an integral counterbalance shaft to reduce vibration


• Designed to work with the donor carburettor arrangement


• Current MY07-16 kits use a three-blade power-valve cylinder

Specifications

• Bore: 89 mm


• Stroke: 82 mm


• Displacement: 510 cc


• Compression ratio: 12.5:1


• Squish clearance: 1.47-2.00 mm


• Primary ratio: 2.25 (72:32)


• Power output: over 60 hp


• Torque output: over 50 ft-lb


• Compatible carburettor sizes: 36 mm or 38 mm


• Piston clearance: 0.10 mm (0.004 in.)


• Minimum fuel requirement: 91-octane petrol


• Premix ratio: 50:1


• Recommended premix ratio for snowbike and desert use: 32:1

Kit Contents

• Exhaust pipe


• Silencer


• Additional fasteners where these differ from the donor engine


• One bent coolant hose to replace the OEM radiator link hose

Build Requirements

• Donor engine or donor engine parts are required


• Uses parts from the original engine to complete the 510 cc build


• Reuses the donor transmission, clutch assembly, kicker assembly, water pump, intake, ignition and covers where possible


• Reuses donor fasteners and dowels where applicable


• The donor engine’s centrifugal power-valve weights in the water-pump shaft are removed and replaced with the supplied spacer as part of the conversion

Important Information

• Shipped on a single small pallet due to the value of the kit


• No warranty is implied or given due to the custom nature of the kit


• All parts should be checked before assembly begins


• US and EU model differences may require modifications to mounts, exhaust or other supporting parts


• A signed waiver confirming acceptance of these conditions is required before dispatch

Vehicle Fitments

• KTM 250 EXC, 2007-2016


• KTM 250 XC, 2007-2016


• KTM 250 XC-W, 2007-2016


• KTM 300 EXC, 2007-2016


• KTM 300 XC, 2007-2016


• KTM 300 XC-W, 2007-2016