BRC 510cc CONVERSION KIT KTM TPI 2020+

This BRC 510cc conversion kit is a custom big-bore package for KTM TPI donor engines, intended to convert a compatible 2020-2023 KTM 250 or 300 EXC/XC-W engine into a 510 cc two-stroke engine. It is a conversion build rather than a direct replacement engine, and it reuses selected original parts from the donor engine during assembly. TPI versions are supplied with a flashed ECU and larger injectors, with maps set for the riding elevations and conditions provided at the time of order.

Features

• Converts a compatible KTM TPI donor engine into a 510 cc two-stroke build


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


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


• Compatible with both kick start and electric start


• Includes a decompression system to assist starting


• Integral counterbalance shaft helps reduce vibration


• TPI version uses a flashed ECU and larger injectors matched to the stated riding conditions

Specifications

• Bore: 89 mm


• Stroke: 82 mm


• Displacement: 510 cc


• Output: 60+ hp


• Torque: 50+ ft-lb


• Compression ratio: 12.5:1


• Squish clearance: 1.47-2.00 mm


• Primary ratio: 2.25 (72:32)


• Recommended fuel: 91 octane or higher


• Recommended additional premix for TPI versions: 150:1 in the fuel tank


• Recommended throttle-body butterfly drilling for TPI setup: 3 mm below 5,000 ft (1,500 m) elevation, 5 mm above 5,000 ft

Kit Contents

• Pipe


• Silencer


• Exhaust manifold


• VForce 4R reed cage (V426)


• 0.3 mm base gasket


• 0.4 mm base gasket


• 0.5 mm base gasket

Donor Engine Requirements

• The conversion uses the engine from the listed application to build the 510 cc engine


• Reused donor parts include the complete transmission, clutch assembly, kicker assembly, water pump, intake, ignition and covers where possible


• EFI/TPI is not supplied for a previously carburetted donor engine


• Donor engines from 2013 onward should use a stiffer clutch diaphragm spring to help prevent clutch slip with the 500 conversion


• The build is designed around readily available service parts including a Vertex Honda CR500 cast piston, Pro-X CR500 rod kit, KTM bearings and seals, and Cometic gaskets


• Earlier BRC500 guidance identifies the stock 36 mm or 38 mm carburettor as the preferred fit for carburetted builds

Assembly and Supply Notes

• Due to the value of the kit, it is shipped on a single small pallet


• Due to the custom nature of the kit, no warranty is implied or given


• Although every effort is made to supply the correct kit, all parts should be checked before assembly begins


• Due to US and EU model differences, some modifications may be required to mounts, exhaust or other supporting parts


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

Vehicle Fitments

• KTM 250 EXC TPI, 2020-2023


• KTM 300 EXC TPI, 2020-2023


• KTM 250 XC-W TPI, 2020-2023


• KTM 300 XC-W TPI, 2020-2023