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FX450 - Rebuild & next bigger piston

Joined Oct 2014
2 Posts | 0+
Montana USA
Hello Gents, I haven't posted in awhile but its time for me to do some refreshing of my FX motor and I am thinking about increasing the displacement.

I am wondering what the next logical bore size is, and what cc that would ultimately be. I guess one thought is a 570cc sized piston on my stock 450 stroke, I am not sure what that would end up being in displacement, or if that is a combination of parts that is a good idea or not. Also would I have my cylinder bored out and resealed or would I want to buy a different cylinder in the correct size?

This FX is my trail bike but it has a license plate and does some road riding to and from the trails. I changed the transmission to FE gears and am currently running 14/52, hoping with a little more torque from the engine I can run 14/50.

Back to the motor rebuild, this unit has about 225 hours on it. I plan on a new piston (the opportunity to go bigger). I am wondering if it would be wise to do crank and rod bearings too instead of just freshening up the top end.

Appreciate any wisdom!
 
Interesting question. I'm pretty green but at least I can point out that the Beta 498 RR has the same bore/stroke as you'd get with a 100mm piston in a 70-deg 450. Seems to be a well liked bike, but surely there are other parts of the puzzle :)
 
Fe 450 = 95x63.4

100mm bore = 497cc

A sleeve or 570 cylinder is needed.

Not sure about the differences in compression height, 570 piston is 24.5mm
 
Contacted Thumper, they have a kit for my motor that has a 102mm bore which is 518cc. I think that will be the hot ticket.

So at 225 hours should I replace the crank and big end bearings while I am in there?
 
Contacted Thumper, they have a kit for my motor that has a 102mm bore which is 518cc. I think that will be the hot ticket.

So at 225 hours should I replace the crank and big end bearings while I am in there?

Travis at Thumper racing could give you his advice on the bottom end, but the answer really varies depending on several factors, namely how the bike was maintained and how it was ridden.

My opinion is that, assuming reasonably normal service intervals and care, the bottom ends of these engines are 400+ hours.

My FX has been ridden hard with good maintenance and it solid as a rock at over 100 hours. Valves have never moved, it uses no oil, and runs very strong still. Most durable and trouble free four stroke racer I have ever owned. It is my back up bike now, as I bought a 2013 KTM 450 SX F, but I'll more than likely have it for a long time because I always will have a real Husaberg in my collection.
 
so what did you end up doing here!? i have fx450 2010. i have 145 h on the motor. replaced the rings... motor ran for 5 hours and something blew on it.... *possibility for foreign objects to have entered my motor IE rust from some dip **** smashing breaks while my motor was open* so now im afraid the rings just ****** up again and the piston and cylinder and messed up. soooo i have to open it up again and see wtf happend. but if i had to replace or bore it out i was REALLY considering going big or going home. how do you like your bike with the over bore? can you give me links to where you got parts, and by how much you bored it out
?
 
Curious

I am also curious what happened here.... I have a FE450 and have been interested in a big bore kit for a while... I think I would prefer a 100mm piston to the 102 offered by Thumper Racing.... I'm thinking the 102 will run hot... Maybe I'm wrong? I would just love to hear from someone who has put the 100 OR 102 on the 63.5mm stroke.

I also considered the 570 crank to duplicate the current KTM 500s bore and stroke of 95mm x 72mm until I found out the 570 has a higher deck height then my 450 so it also requires the 570 cylinder to work.... SO.... The only real option on the FE / FX 450s are to go bigger bore... I assume....

Again... Would love to find a KTM wizard who really knows these engines... Someone who would know what parts would interchange... I just read today that the KTM SX camshaft might prove to be a good upgrade to our bikes.....
 

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