Here is my latest project, turbocharging my 2012 KTM 500 EXC
Today i put it on the dyno.
The result was better than I expected.
Peak power 96,86 hp at 10,1 pounds of boost.
Stock power was 55,6 hp.
Putting up some photos of by build. The dyno charts comes at the end of this post.
Running a rear mount layout. Keeping the exhaust stock. Just replacing the muffler with the turbo. I believe that rearmount is good at smoothing out the powerful exhaust pulses that can be a problem when turbocharging single cylinder engines.
Using a pressure lubricaded non ballbearing turbo. Took a oilfilter cap from a KTM690 which have a threded hole to connect the oil feed line.
One thing that is good with the KTM500 is that it has pressure lubricated big end connecting rod bearing. Most of dirt bikes have roller bearing and a very low oil pressure
Checked the oil presure with a guage, over 46 PSI. Mitsubichi have a recomendation at minimum 37 if I recall.
Now I can be sure that the turbo get the correct lubrication-
The biggest job in the project was designing and building the plenum. Tried to use all the avaliable space to get a very large plenum.
Started with a mockup out of wood then make it in 2 mm aluminum.
The volume of plenum endet at about 4-5 liters.
The triangular thing on the side is a mount for BOV.
Using the MCXpress piggyback fuel injection. A extra fuel injector in plenum delivers extra fuel.
Fuel rail
The injector is placed just at the intake of the throttlebody.
Bigger power reqires a firmer chlutch. KTM using beleville spring. Order another spring and just put in over the stock spring. Now I have double spring force.
A adaptor at the oil fill plug connects the oil return line from turbo
Pressure oil feed from oil filter to turbo
Put isulating wrap around the exhaust.
Not a very good looking mount for the temprary intercooler but it's just for puting it on the dyno. I will later make a smaller and mount it on the tube frame of my snowbike.
Dyno test at MCXpress.
The results looks promising from start. Just over 84 hp at moderate 8 PSI.
Checking with lambda guage to get right air fuel ratio.
Finally the tuning is done. Must say that restults exceeded my expectations! The theoretical power and the final result was pretty spot on. That shows that it's running very good.
Peak power 96,86 hp at 10,1 pounds of boost.
Torque 85 Nm
Today i put it on the dyno.
The result was better than I expected.
Peak power 96,86 hp at 10,1 pounds of boost.
Stock power was 55,6 hp.
Putting up some photos of by build. The dyno charts comes at the end of this post.
Running a rear mount layout. Keeping the exhaust stock. Just replacing the muffler with the turbo. I believe that rearmount is good at smoothing out the powerful exhaust pulses that can be a problem when turbocharging single cylinder engines.
Using a pressure lubricaded non ballbearing turbo. Took a oilfilter cap from a KTM690 which have a threded hole to connect the oil feed line.
One thing that is good with the KTM500 is that it has pressure lubricated big end connecting rod bearing. Most of dirt bikes have roller bearing and a very low oil pressure
Checked the oil presure with a guage, over 46 PSI. Mitsubichi have a recomendation at minimum 37 if I recall.
Now I can be sure that the turbo get the correct lubrication-
The biggest job in the project was designing and building the plenum. Tried to use all the avaliable space to get a very large plenum.
Started with a mockup out of wood then make it in 2 mm aluminum.
The volume of plenum endet at about 4-5 liters.
The triangular thing on the side is a mount for BOV.
Using the MCXpress piggyback fuel injection. A extra fuel injector in plenum delivers extra fuel.
Fuel rail
The injector is placed just at the intake of the throttlebody.
Bigger power reqires a firmer chlutch. KTM using beleville spring. Order another spring and just put in over the stock spring. Now I have double spring force.
A adaptor at the oil fill plug connects the oil return line from turbo
Pressure oil feed from oil filter to turbo
Put isulating wrap around the exhaust.
Not a very good looking mount for the temprary intercooler but it's just for puting it on the dyno. I will later make a smaller and mount it on the tube frame of my snowbike.
Dyno test at MCXpress.
The results looks promising from start. Just over 84 hp at moderate 8 PSI.
Checking with lambda guage to get right air fuel ratio.
Finally the tuning is done. Must say that restults exceeded my expectations! The theoretical power and the final result was pretty spot on. That shows that it's running very good.
Peak power 96,86 hp at 10,1 pounds of boost.
Torque 85 Nm
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. I'm really excited over the dyno result. This looks promising.
