2003 KTM 550 SXS Smets replica

saunders126
Edited Date/Time 10/23/2022 10:13am
Hey guys, I found a beat up 2006 450 smr that I’m fairly sure is an ex Australian supermoto race team bike. Cosmetically it’s toast. But the bones are all still in pretty good condition with the exception of a few things. And I picked it up really cheap.

The plan is to strip it to a bare frame and rebuild it as either 2005 Ben Townley 450sxs or a 2003 Joel Smets 450 replica. Either way it’s a good base to start from. Apologies for not getting good photos before stripping it down














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saunders126 10/15/2022 4:50pm
10/15/2022 4:50pm Edited Date/Time 10/15/2022 4:52pm
List of notable parts it came with
SXS Closed cartridge forks
SXS Shock
SXS 2 piece clutch cover
SXS/Powerparts slipper clutch
6 speed gearbox
Flowed cylinder head
Split stream carb intake and Ikat spark enhancer 😂
Complete Akrapovic system
SXS fuel cap
SXS front disc
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JMX82
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JMX82 10/19/2022 2:36am
10/19/2022 2:36am
You got some really nice rare SXS stuff with the bike! Good luck with the build!
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Gravel
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Gravel 10/20/2022 8:45pm
10/20/2022 8:45pm
It’s got the tall cylinder, very possible it’s a 525 or bigger. The short stroke 450 has a cylinder that’s something like 8mm shorter. Measure the bore, 95mm is a 525 (510cc actually), bigger is more!
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JMX82
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JMX82 10/21/2022 4:42am
10/21/2022 4:42am
Gravel wrote:
It’s got the tall cylinder, very possible it’s a 525 or bigger. The short stroke 450 has a cylinder that’s something like 8mm shorter. Measure the...
It’s got the tall cylinder, very possible it’s a 525 or bigger. The short stroke 450 has a cylinder that’s something like 8mm shorter. Measure the bore, 95mm is a 525 (510cc actually), bigger is more!
There was 540cc SXS kit available back then. It might be even that one

https://aomc.mx/SXS03540550.html
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saunders126 10/21/2022 9:23am
10/21/2022 9:23am
Thanks guys! Ah no way, I didn’t even see that. I’m pretty new to the RFS engines so I’ve got lots to learn. I’ll let you know what it is when I strip the engine down.

I did some digging and I think they did 2 different versions of the 540sxs kit depending on the age. I think they did a 97mm piston 72mm stroke version, and a 100mm piston with maybe 68mm stroke? I know the 100mm cylinder is much different looking, the water jacket is huge
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Gravel
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Gravel 10/21/2022 2:11pm
10/21/2022 2:11pm
saunders126 wrote:
Thanks guys! Ah no way, I didn’t even see that. I’m pretty new to the RFS engines so I’ve got lots to learn. I’ll let you...
Thanks guys! Ah no way, I didn’t even see that. I’m pretty new to the RFS engines so I’ve got lots to learn. I’ll let you know what it is when I strip the engine down.

I did some digging and I think they did 2 different versions of the 540sxs kit depending on the age. I think they did a 97mm piston 72mm stroke version, and a 100mm piston with maybe 68mm stroke? I know the 100mm cylinder is much different looking, the water jacket is huge
https://ktmtalk.com/showthread.php?367448-Evolution-of-the-RFS-engine

I’ve got an 06 RFS, mine is a 450xc, that’s a short stroke 6 speed with e-start. I did a 99mm big bore for a 490, it’s a sweet combo.

Look around, there might be e-start kits still available. Take care of your cam and countershaft, availability is getting tough for them, although there is aftermarket countershafts out.

Great bike!
2
Rickyisms
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Rickyisms 10/22/2022 5:50am
10/22/2022 5:50am
Is that an SXS brake tip too?

That’s a really cool bike with some super trick parts! Excited to follow this one.
saunders126 10/22/2022 8:20pm
10/22/2022 8:20pm
Gravel wrote:
https://ktmtalk.com/showthread.php?367448-Evolution-of-the-RFS-engine I’ve got an 06 RFS, mine is a 450xc, that’s a short stroke 6 speed with e-start. I did a 99mm big bore for a...
https://ktmtalk.com/showthread.php?367448-Evolution-of-the-RFS-engine

I’ve got an 06 RFS, mine is a 450xc, that’s a short stroke 6 speed with e-start. I did a 99mm big bore for a 490, it’s a sweet combo.

Look around, there might be e-start kits still available. Take care of your cam and countershaft, availability is getting tough for them, although there is aftermarket countershafts out.

Great bike!
Thanks mate, that thread you shared is unreal. Tons of information on it and good to read through. No worries, I’ll watch for wear on those bits when I tear it down
saunders126 10/22/2022 8:21pm
10/22/2022 8:21pm
Rickyisms wrote:
Is that an SXS brake tip too?

That’s a really cool bike with some super trick parts! Excited to follow this one.
SXS factory tip complete with wood screws and rivets haha
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saunders126 10/22/2022 8:26pm
10/22/2022 8:26pm Edited Date/Time 10/22/2022 8:27pm
I had a chance to take a quick look at the engine yesterday, and turns out I’ve hit the jackpot. It’s got the 97mm big bore cylinder and the 78mm factory stroker crank in it. 576cc


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KTM Two Stroke 10/22/2022 11:33pm
10/22/2022 11:33pm
saunders126 wrote:
I had a chance to take a quick look at the engine yesterday, and turns out I’ve hit the jackpot. It’s got the 97mm big bore...
I had a chance to take a quick look at the engine yesterday, and turns out I’ve hit the jackpot. It’s got the 97mm big bore cylinder and the 78mm factory stroker crank in it. 576cc



Checked the KTM Spareparts Finder there was no 525 SXS made just a 450 SXS from 2003-2006 so you found a very Special bike

I follow your build that Era was one of the best looking KTM‘s ever for me


Shane_Robinson 10/23/2022 1:50am
10/23/2022 1:50am
saunders126 wrote:
I had a chance to take a quick look at the engine yesterday, and turns out I’ve hit the jackpot. It’s got the 97mm big bore...
I had a chance to take a quick look at the engine yesterday, and turns out I’ve hit the jackpot. It’s got the 97mm big bore cylinder and the 78mm factory stroker crank in it. 576cc


KTM Two Stroke wrote:
Checked the KTM Spareparts Finder there was no 525 SXS made just a 450 SXS from 2003-2006 so you found a very Special bike I follow...

Checked the KTM Spareparts Finder there was no 525 SXS made just a 450 SXS from 2003-2006 so you found a very Special bike

I follow your build that Era was one of the best looking KTM‘s ever for me


Ktm made a 540sxs 02-05
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Gravel
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Gravel 10/23/2022 10:05am
10/23/2022 10:05am
RFS KTMs are pretty modular, what I’m guessing you have is a 06-07 frame, because your chassis looks identical to my 06 that I bought new and still own, and a 05 or later motor that someone did a great build on. When you get that thing back together it’s gonna be a sweet ride!
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Gravel
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Gravel 10/23/2022 10:13am
10/23/2022 10:13am
Gravel wrote:
https://ktmtalk.com/showthread.php?367448-Evolution-of-the-RFS-engine I’ve got an 06 RFS, mine is a 450xc, that’s a short stroke 6 speed with e-start. I did a 99mm big bore for a...
https://ktmtalk.com/showthread.php?367448-Evolution-of-the-RFS-engine

I’ve got an 06 RFS, mine is a 450xc, that’s a short stroke 6 speed with e-start. I did a 99mm big bore for a 490, it’s a sweet combo.

Look around, there might be e-start kits still available. Take care of your cam and countershaft, availability is getting tough for them, although there is aftermarket countershafts out.

Great bike!
saunders126 wrote:
Thanks mate, that thread you shared is unreal. Tons of information on it and good to read through. No worries, I’ll watch for wear on those...
Thanks mate, that thread you shared is unreal. Tons of information on it and good to read through. No worries, I’ll watch for wear on those bits when I tear it down
Dave Hopkins, the guy who wrote the RFS thread linked, is one of a handful of RFS experts who truly know the platform. He did a fantastic job rebuilding the head on mine when I did the big bore kit.
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saunders126 10/23/2022 12:33pm
10/23/2022 12:33pm
Gravel wrote:
RFS KTMs are pretty modular, what I’m guessing you have is a 06-07 frame, because your chassis looks identical to my 06 that I bought new...
RFS KTMs are pretty modular, what I’m guessing you have is a 06-07 frame, because your chassis looks identical to my 06 that I bought new and still own, and a 05 or later motor that someone did a great build on. When you get that thing back together it’s gonna be a sweet ride!
For sure, it’s definitely an 06 450 smr platform as both the vin plate and engine number read that and check out. I just took it as gospel as far as the engine capacity.

I think it’s an ex Aussie race team bike as why it has so much cool stuff, I just assumed they would have used the a 525/560 as a base for the open class so I didn’t think any more of it.
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saunders126 8/19/2023 10:47am
8/19/2023 10:47am

It’s been a little while since I’ve done an update. This is the exact bike I’ll be building a replica of. I’ve been collecting parts in the mean time and found some really cool stuff. I managed to score a 2003 factory Smets seat, a 2002 works WP Shock and even the correct factory cable clutch assembly that Joel used to run 

IMG 0597

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