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  • 1 Post By WArdogG
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May 21st, 2017, 03:21 AM   #1
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Joined: May 2017
From: Australia

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2004 fe550 ≥ 450 conversion

Hi guys,
I'm a newbie from Melbourne and was wondering if any one had converted a fe550 back to a 450and what's​ involved, any help would be appreciated

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May 21st, 2017, 09:14 AM   #2
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From: Chilliwack, BC, Canada

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I Ride: 2014 FE350, Beautiful Blonde
Question is WHY???????

Be easier on da throttle
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May 21st, 2017, 10:31 AM   #3
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From: Iceland

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I Ride: 1 Berg, 1 Zook
The engine cases are different And a host of other things. You'd need a 450 motor. I don't think it drops in (exhaust?).

Don't - for god's sake keep it as a 550!, - if you must have a 450, buy one / swap.
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May 31st, 2017, 08:50 AM   #4
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From: South Africa

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I Ride: FS650 '08/FS650 '04/FE501 '03/FX470 '02
But why? If you really want to make it a 450, you would have to fit about a 90mm piston to get close to 450cc. The KTM 525 and the KTM450EXC share the same 72mm sroke, 525 has a 95mm piston and the 450EXC uses an 89mm piston, this piston could work and would give 436cc, the deck height on the KTM piston is 0.5mm higher than the Berg, so you would have to machine that off. Be sure it's the 89mm piston from an EXE model, the 450SX uses a different bore X stroke than the enduro models. Swapping a bottom end will not work, as Tourist said, the cases are different.

But why...?
Thanks from bushmechanic
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May 31st, 2017, 10:21 AM   #5
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From: Sacramento California

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I Ride: "2000" FE600, 1996 FC660, 2015 Beta Xtrainer
I wonder if a 380 kit could be used (if they can still be found)? That's a 92mm piston and would result in a 465cc engine.
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May 31st, 2017, 01:27 PM   #6
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From: Simi Valley Ca.

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I Ride: 2006 FS650e, 2007 FE550e, 2016 Ktm500Exc
Have you thought about trading it. You might be able to end up with a newer 450 from someone wanting the faster bike.

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May 31st, 2017, 06:42 PM   #7
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From: Burlington

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I Ride: '07Exc 525 & '07 FS 550.Just sold ' 08 Ktm 450 sxf.

If powe is too aggressive then it can be detuned easy. Restrict air flow and possibly might need to re jet it. Jets alone would probably do it too. If you are new to the bike just give it some time and I assure you will get used to it. Then you will fall head over heals for it. U won't be looking back. Older gentelman sometimes want softer power and thats totally understandable. No need for any friggin 250😒.
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June 6th, 2017, 04:45 AM   #8
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From: Germany

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I Ride: Husaberg FE 501 2002
You should be happy for having the 550. After some time you'll get used to it...
I don't know if any of these make sense:
  • Throttle Tamer
  • less ignition advance
  • thicker head gasket

The throttle tamer should reduce the throttle valve lift - in theory - never had one.
Thicker head gasket should reduce engine compression ratio. Less overall power

Manipulating the ignition advance is more complicated - maybe not needed.

When you ask me - learn to ride the 550 That's time well spent!!!
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June 7th, 2017, 03:06 PM   #9
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From: Brisbane Australia

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I Ride: FE650
Throttle tamer works. I put one on my 950 to take away the low down snatch.

You can also put a smaller sprocket on the rear.
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