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Popular Setups by Brand

This is a list of some of the most common bikes we work on and some of the best value for money mods by brand. If your model/year is not listed here contact us to see what we suggest… just cause we haven’t listed it on this page DOES NOT mean we dont have the answers to getting the most from your engine without spending a fortune.

Before you waste money on aftermarket pipes, mufflers or heads you should seriously consider the mods listed below for each model as they represent the BEST BANG FOR YOUR BUCK that you will spend on these bikes. In many cases the stock exhaust system will produce the broadest spread of power on the dyno.

These setups will make a big difference to power and reliability and will suit 90% of riders but they are they are NOT necessarily the most powerful setups we can offer, they are just the minimum we recommend to get your engine singing…. so if you really need the absolute most from your engine then contact us because there is always lots more we can do.

The prices listed below are the modification cost only and DO NOT include the labour to remove or refit components or rebuild parts such as pistons, gaksets, bearing, etc (unless specified otherwise). Our standard labour charge is $99/hr inc GST for removing and refitting parts and rebuilding engines. You can either send the whole bike, the whole engine or you can remove the parts yourself and send them to us to work some magic on.

 

 

Honda

  CR250

CR85

For trailriding we suggest setting up the head for better bottom end ($240) and if you really want to shift the power lower for beginners consider machining the cylinder base ($110)… this can later be reversed by adding extra base gaskets if necessary.

For MX racing you will need to setup the head ($240) and you should consider Advanced Porting ($350) to make them as competitive as possible through the midrange and top end. For all serious MX setups we suggest Dyno Tuning ($350) to fine tune the overall package… it can REALLY make the difference between a good engine and a WINNING engine.

CR125

For trailriding setup the head to correct squish clearance and compression ratio ($240). Standard Porting also helps to improve throttle response and power throughout the rev range ($220). For MX they not only need the head setup but also benefit a huge amount from Advanced Porting ($350) to significantly increase power in the midrange and top end with no loss of bottom end.

We also offer 134, 139 and 144 big bore conversions for $1099

CR250

The pre 2002 CR250s are great engine and aside from setting up the cylinder head properly ($240) they dont need much… unless of course you are chasing massive power.

The 02+ Honda CR250’s are great bikes but they have weak bottom end power, huge midrange and then fall flat up top. They also detonate and are very difficult to jet properly. At a minimum they need the cylinder head setup properly ($240) and respond very well to fitting a different carb ($POA). Doing these two mods will totally transform the engine and make it suitable for both trailriders and racers alike… you will be amazed at how much difference it makes! This is a MUST DO mod for this bike… dont waste money on any aftermarket mods until you sort the head out.  We can source new or second hand carbs for a reasonable price and also modify the wiring for the Throttle Position Sensor. Standard Porting ($220) also goes a long way with these engines and helps to improve throttle response and power throughout the rev range for trailriding. If you’re racing MX then Advanced Porting ($350) makes them more competitive up top with KTMs and YZs.

We also offer 265 and 295cc conversions for $1199

CR500

The stock CR500 has poor low end power (given its capacity), massive midrange power and then signs off very early after peaking at only 5800rpm. It can be a handful to ride offroad or on an MX track due to the hard hitting midrange power. The stock head design is very bad and the stock porting doesnt allow the engine to rev out properly. Regardless of your style of riding at a minimum the CR500 MUST have the head setup properly ($240). Due to the angled spark plug we do this particular head on our CNC mill to ensure perfect dimensions. This mod makes a huge difference to power and reliability. It almost totally eliminates detonation and allows the engine to rev much smoother and harder. Advanced Porting ($350)  is the next best thing you can do to this engine… it allows the engine to rev out much smoother and much harder and actually makes the bike much easier to ride in all conditions. The final important mod you should consider for this engine is fitting a properly jetted Keihin PWK carb (approx $400 for a new carb with TSP dyno proven jetting specs). This makes a big difference to power and throttle response and is a big improvement over the stock carb.

 

Husaberg

TE125/250/300 2011-2013

TE250

See notes for KTM models as they share the same engines.

 

Husqvarna

 

WR300

WR250/300 up to 2013

The head design on these engines is very poor and then benefit massively from setting up the cylinder head properly ($240). This will give better fuel economy, better throttle response and much better low/mid power. Overall they become much easier to ride offroad once this is done. We have also set up plenty of these engines with Standard ($220) and Advanced Porting ($350) and the gains can be very big. We can also convert them to a 6 speed transmission from the standard 5 speed. The powervalve setup often needs attention and its worth having the powervalve fully stripped and checked at each top end rebuild.

 

Husky TE250

TE/TC 125/250/300 2014+

See notes for KTM models as they share the same engines.

 

 

KTM

KTM250exc

50/65/85 SX

For trailriding we suggest setting up the head for better bottom end ($240) and if you really want to shift the power lower for beginners consider machining the cylinder base ($110)… this can later be reversed by adding extra base gaskets if necessary.

For MX racing you will need to setup the head ($240) and you should consider Advanced Porting ($350) to make them as competitive as possible through the midrange and top end. For all serious MX setups we suggest Dyno Tuning ($350) to fine tune the overall package… it can REALLY make the difference between a good engine and a WINNING engine.

 

125/150/200 SX/XC and EXC models

These models share the same basic engine platform with varying bore and stroke. These engines have huge potential, however in stock form they have some issues that need fixing to get the most from them. All of them need the head setup properly ($240) and we strongly suggest Standard Porting ($220) at a minimum for serious trailriders and offroad racers to correct some issues with the cylinder casting, powervalve design and some big mismatches between the cylinder and cases. For MX racing we suggest Advanced Porting ($350) to make them as competitive as possible and to increase mid and top end performance… this can be done without any risks to reliability and with no loss of bottom end performance. 38+rwhp is possible from the 125 and a modified 200 will reach 44rwhp without pushing it too hard and rev to 12,000rpm… for comparison a stock 250SX is 46-47rwhp. EXC and XC models with a 36mm carb can seriously benefit form a carb oval bore to 36/39mm ($220) plus some secret TSP ignition mods ($110)… these two mods really complete the XC and EXC models and see them match an SX for performance any day.

Our most popular package for EXC and XC models includes Head Setup, Standard Porting, Carb Oval Bore and Ignition Mods for $1200 including specialist top end rebuild labour (piston, gaskets and other parts are extra if required). This setup makes a MASSIVE difference to power everywhere above idle, with better fuel economy than stock and no risk to reliability.

 

250/300 SX/XC and EXC models

These are very well designed engines but there are a few key areas that can be improved upon. Firstly setting up the head correctly ($240) is essential for ALL 250/300 models, including the SX. The 2014+ models especially have a terrible head design and need some major machining to get them running to their potential. Standard Porting ($220) makes a big difference to power throughout the rev range and for serious MX racers we can get the 250SX to pump out over 60hp (7hp more than stock) with our Advanced Porting ($350) with no loss of bottom end (in fact you will get major gains everywhere above idle). All models benefit from a 36/39mm carb oval bore ($220) and the XC and EXC models massively benefit from our ignition mods ($110) as well.

Our most popular package for EXC and XC models includes Head Setup, Standard Porting, Carb Oval Bore and Ignition Mods for $1200 including specialist top end rebuild labour (piston, gaskets and other parts are extra if required). This setup makes a MASSIVE difference to power everywhere above idle, with better fuel economy than stock and no risk to reliability.

We also offer a 330cc big bore top end kit for the 300 models for

 

 

 

 

 

 

 

 

 

 

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