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
NOTE* UK SHIPPING COSTS MAY VARY DEPENDING ON ZONE. INTERNATIONAL SHIPPING IS WELCOME IF YOU ARRANGE IT YOURSELF (INSURED)
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