Turning a KTM 450 from enduro to adv to hipster to the ultimate lightweight adventure bike

[@GreenString]

Respect to any man who loves his bike and refuses to replace it. Stay safe mate.

[@GregVillalobos]

Ha thanks! :-)

[@jotemenkir]

Me every time: Hmm... nearly an hour long video of a bike I don't own nor do I really care to own. Why would I watch it? Also me everytime after sitting glued for nearly an hour: Really great editing and story telling. Very glad I sat through it. If only he'd put out more of these videos. P.S. The bike looks badass!

[@GregVillalobos]

Ha! Thanks Jote! I would make more but I think the family would have something to say. Adventure Spec gets most of my working hours these days so there's more to see over there. :-)

[@JackRiverD]

Hey Greg, just wanna say I like your style; being honest about your mistakes and uncertainties - makes me feel very comfortable. Glad you’re putting the bike in; I had starting problems on my DRZ which turned out in the end to be valve clearance but led to a sketchy morning in the mountains relying on some helpful 4wd’ers to get me going. Your bike will thank you and repay you with that reassuring sound of an easy start.

[@GregVillalobos]

Thanks Jack! I look forward to getting my 450 back in the garage :-)

[@HunnyBadg3r]

I just got a KTM 450. I listened to your 2 videos and took notes throughout. I feel more comfortable going in to this build with it's various problems and successes. As I've watched the progress I'm very pleased to hear you've enjoyed yours!

[@GregVillalobos]

Thanks! Enjoy the new bike

[@RebellionTroll]

Love your videos from start to finish! I feel I can understand your way of reasoning things and the fact that you don't just drop thousands of £££ on an old bike to make it work. In fact after a lot of self debate about what bike I want next as my go to dual sport and "daily" bike you amongst others convinced me that a 450 exc could be the bike I'm looking for

[@GregVillalobos]

Thanks Stefan! Hope you enjoy whichever bike you get next

[@chrismanley5656]

I absolutely love what you’re doing, I love your honesty about the aesthetic, I love your hands on approach. Two things, never underestimate the skills you have, you are a full blown shed bike builder, custom screens, all the work yourself, everyone buys parts!!! Next, aesthetics are so important to your enjoyment, you emotional attachment to the thing, the love of twisting the throttle is so much enhanced by the feeling of walking up to it and the looks over the shoulder as you walk away. James Hoffman completely change my opinion on so much of what is important for enjoyment, and it’s the whole thing, the feel, the sound, the smell, the look and the history of the thing. Something about how he does coffee is some enlightening about the meaning of life, feeling the whole thing, being critical about the whole experience not just one aspect. Thank you so much for your work Greg! Amazing stuff!

[@GregVillalobos]

Thanks Chris!

[@guille_snapshooter]

i just can say thank you greg, its so refreshing to see no gear BS, no bike BS of the latests and greates new something. just take what you got and make it work !, and that its 100x more inspiring to go out than just think we cannot go outside and have great adventures because we dont have new things.

[@GregVillalobos]

Thanks! Go with what you got. If you want to hear me talking about shiny new things I can help with that too ;-)

[@guille_snapshooter]

@@GregVillalobos "Go with what you got", i can relate complitely on this, last year before my trip to Carretera Austral, i was thinking on what luggage should i buy for the trip, and at the end went with what already have, plus some new straps ! jaja, and i work out way better than expected.

[@AleksanderTrlik]

When I watch this, I can see myself four years ago and my second Yamaha XT600Z Tenere. A great machine, but after buying it, the first thing I did was spend a year on its appearance and adaptation to myself. All my friends started to remind me why I should change the original, why I play with it and spend money unnecessarily, but only some understand that such a motorcycle has its own soul and making it under yourself emphasizes it, somehow it connects you more with the machine and thanks to that at least I am more associated with such a machine. May your modifications give you the same feeling as me.

[@GregVillalobos]

That's bang on. The bike becomes a reflection of the rider :-)

[@grahamrowe6278]

Great contribution Greg... Proper real-world stuff.

[@GregVillalobos]

Thanks Graham!

[@losing_myself]

Your bike has been an inspiration for my 400exc. That is the exact headlight I've been looking at but was trying to figure out the fairing. Thanks for the information and great video too.

[@GregVillalobos]

Glad I could help!

[@CarparkCarl]

Nice one Greg! Always love these long format videos! Definitely looks cool af with that cyclops headlight unit!

[@GregVillalobos]

Thanks! I do love the Cyclops.

[@CarparkCarl]

@@GregVillalobos no no, thank you!

[@elvisparsley7497]

Hi Greg, You are following my ethos almost exactly. I love the content, the insight and above all the retro bike vibe. This is exactly what I try to achieve with most of my bikes...road and dirt. I'm not a big fan if the over-styled fashion over function look in either category but a nod to the retro in the off-road sector certainly helps with a little acceptance with the unnaitiated when out on the lanes. I am currently choosing a base for a lightweight adventure/duel sport donor bike. WR450, EXC400 '05 - '17, budget pending as ever. Keep it coming and keep it retro! 😃👍

[@GregVillalobos]

RETRO FOR EVER! :-)

[@ogasi1798]

ktm make great bikes - been with them for such a long time

[@johnmaclean190]

Hi I agree a rounded tank would be a lot better. I have also resorted to a Dremel to extract snapped bolts. Works well but takes loads of patience.

[@GregVillalobos]

Wouldn't it be nice if someone made a retro tank.

[@OnThrottle]

Fantastic vid as always. Your style of nodding the bike to keep it fresh and the enjoyment high has rekindled my love for my own bike.

[@GregVillalobos]

Thanks! Your bike will be grateful of the attention :-)

[@AYYOFLOCKA]

Really informative! My first kid is just about to go into childcare so I feel you on skint-ness. Enjoy having that ktm to the fullest it's an amazing machine, it lets folks like me who can't afford one right now live vicariously through this documentation and films :-)

[@GregVillalobos]

Thanks! On the plus side, if the kids are in childcare it's the start of getting some of your own time back. ;-)

[@Adameftube]

Aluminium oxide dremel heads. I've been there with header bolts on my SV650. Nearly had to remove the whole engine to take it to get it fixed. I'd never use "easy outs" again. As they are tapered they put more and more pressure on the seized bolt sidewalls as they go in and snap. They're hardened steel, harder to drill out than the original bolt. Now I go straight for heat and cold (good blowtorch such as a Rothenberger followed by freezing spray, more heat, more spray) and then use left handed drill bits starting very small and getting bigger. It took two weeks lying on a freezing floor in winter swearing under my SV to come to this conclusion.

[@Adameftube]

+ If you're going to do swingarm and linkage bearings then a Rothenberger Superfire 2 blowtorch would be a good investment before you do. Not cheap but mine has had so much use doing bearings on my DRZ.

[@GregVillalobos]

Great tip Adam. I don't have a blowtorch in the garage so will take a look

[@gnarlybadger690]

A grin to a grimace then back to a grin………… sounds like typical KTM ownership, can’t think why I sat watching the whole of this video about some guy and his old KTM especially the pauses when your replaying memories in your head 🤔🤣. My Kato is not quite as old as yours but I think i may feel the same way. Thanks for sharing Greg and I honestly did enjoy watching 😉

[@GregVillalobos]

Thanks Pete!

[@lancepoteet2172]

I always wanted to throw one of those on my drz400 and ended up building my own which got lots of compliments, it was far from round.. I bought a 14’ 500 exc last year I’ve been giving a face lift and I’m down to the headlight as well.. think I’m sold on the standard rally tower.. but at a hefty price tag. Unfortunately your little fairing won’t work with my brp mounts.. had to contact them to ask. Loving the new look of the 450!

[@lancepoteet2172]

Also.. I highly recommend a rekluse clutch.

[@GregVillalobos]

Thanks Lance! Hope you enjoy the 500. I've thought about a Rekluse but maybe I'm a bit old school, I kinda like the simplicity of leaving the clutch alone. :-)

[@vicepride2568]

Cool vid mate.. I have been looking into getting a 990 Adv… you now got me to reconsider that for a 450 EXC

[@GregVillalobos]

Thanks! I think the 990 and 450 are quite different bikes so it really depends what you are doing with it. Both will be fun!

[@bmwe30guy]

I've ridden my 990 in far gnarlier conditions than many would imagine, and loved every minute of it. Can't beat the induction sound

[@pritsalian1473]

As usual, a great film! And really please to see how the bike is coming up, it looks smashing.

[@GregVillalobos]

Thanks!

[@alpen4921]

Just stumbled across your channel. Good story 👍 I bought a second hand 2012 exc during lockdown as I was living with me ex and her family on a small holding in the New Forest and thought I’d take advantage of the easy access to the Hampshire trails and improve my bike riding ability. Shortly after the easing off lockdown she gave me my marching orders and now I’m back in central london and it’s such an effort to get out and find anywhere to make use of the bike but I’m heavily invested in the bike and kit I’d be gutted to let it go. So your long range adventures have given. E hope and as soon as my broken collarbone heals (another long dirtbike related story) I think I’ll plan a trip to Europe too. The only mod I’ve done so far (not mechanically minded either) is try to upgrade the light as it’s all but useless. It’s not gone so well. I got a 3x3 row led headlamp (from some eBay site)but can only get the top row of lights to come on and once, go ing home from a day out with the TRF, they didn’t come on at all and I’m completely stumped as to why they don’t work. This has led me to consider the baja design light but they are so expensive I’m a bit worried I’m about to waste more money, I liked you light but I prefer the look of the standard light and shroud.

[@GregVillalobos]

Hope you are getting on well with your build :-)

[@alpen4921]

Hi Greg, good to hear from you. I haven’t managed to do anything with regards the light yet…. Still not been out on the bike since breaking my collarbone in April. Doc says another 6 weeks and I should be fully healed. That’s almost a 6 month recovery time. I’ll start slowly with a few more TRF events but now I’m considering a TET tour back to Portugal to catch up with Diogo. I’m thinking a 3 week trek around April next year. At the moment the only thing putting me off is having no one to come with me…. If your interested, mores the merrier and if you have any ideas to share about my light issues that would be greatly appreciated.

[@Bikerdad_85]

What a great video 👍🏻. Love your set-up. Very similar to my setup. Very minimalistic. I put over 60k miles on my drz 400 before a garbage truck ran over my bike. Fortunately for me , when that happened the bike was parked. Bought that bike brand new. Looking forward to be on a new bike ASAP. Great video and ride safe brother 👍🏻

[@GregVillalobos]

Thanks! Best of luck with the new bike hunt

[@everydaybiker]

I think I'm going to have to follow Greg's lead. The 701 is going, light is right 501 build is in the future.

[@davedavis3304]

Hi Greg, ref the countershaft seal, look at Keith Jobsons vid.. could be the compression washer (if not already replaced) at fault not the seal. Ridden most of what you have done so far on a fully modded DR650, now looking forward to taking my prepped exc 500. Keep up the enjoyable and informative vids.

[@GregVillalobos]

Thanks for the tip!

[@MrBurtmeister]

Enjoyed the details of your KTM experience. I Bought the CRF 300 last year and now want an EXC 500. The service intervals are not as bad as I first thought. The clutch story reminded me of when I rode back home on from France without a throttle cable. I wound up the tick over screw and used the kill switch to change gear and slow down. .. Happy travels Greg!

[@GregVillalobos]

Ha! That's an epic DIY job. Well done! The 300L and 450 are the same but not the same. :-)

[@jeremycornishjc]

Giving me inspiration to sort my 525 out for a lightweight adv/tet bike

[@GregVillalobos]

Get it done!

[@iamdorusyt]

Great film Greg! Your bike is super cool, I really like look of the front end with the mini fairing. I would like to do somethings similar with my bike, you've got some great inspiration.

[@GregVillalobos]

Thanks!

[@larskessel3949]

Very good and informative video. Really like the look of the Katoom with the Cyclops headlight and the mini fairing. Well done!

[@NorthWestEnduro]

Pre 2017 ktms seem to be alot better built than the newer bikes. Best to keep this one running!

[@GregVillalobos]

That's the plan! :-)

[@basvanderzouwen2193]

What a great jurny and nice way of telling it! Have to make a choice myself to get one. Want to get into riding dirt but i ride a lot of road miles as well. I don't have the mony to buy a big adventure bike. Maybe building it myself over time is a cool project. Thit made me feel like its posible! Thanx for sharing your story!

[@GregVillalobos]

Thanks!

[@DF4Trap]

Great story, love the bike, thanks for sharing.

[@GregVillalobos]

Thanks!

[@trailwayfilms]

Adams a genius with the mirror trick. Now I don't need to take a cd case camping..😆

[@GregVillalobos]

Adam's got all the moves...

[@csbalazs01]

Two kind of riders are: 1. Loves the Ktm 2. Hasn’t got Ktm yet Thanks for the video

[@GregVillalobos]

HA! I do know a third kind of rider but lets not talk about him... ;-)

[@andyholmes999]

Enjoy your video's Greg. Inspirational, just got a 500excf to try out the TET this year and international next year. Hopefully see you out there. Likely pop over to your shop soon too, im only in West Lancs..... try out your clothing line and the obligitary TET stickers :)

[@josealcaraz1575]

Gracias por contarnos tus experiencias, sin duda siempre aprenderemos!

[@pgkr67]

Great video Greg. I do hope that when you talk about hydraulic fluids for the clutch you mean brake fluid. You have a Brembo master and it uses Dot4.

[@GregVillalobos]

Yup its DOT 4. I was referring to the point that it's a hydraulic clutch, not a cable clutch :-)

[@ogasi1798]

just watching again as it is a great series and as an exc500 owner we are somehow distantly connected - so , after the rebuild where is the bike at in your life? Tip top and happy ?

[@GregVillalobos]

Bike is approaching 30,000km and 700hrs - it's running well

[@ogasi1798]

@@GregVillalobos nice, mine is at 300 hours and tickety boo

[@garyfolz7202]

Great video; got lots of info. i like the uprades,good taste... i have KTM 500... this is why i watched..............am here in the Midwest , UStates

[@richardcripps318]

They are great bike i love them , iam on my 2014 exc 500 two weeks into cape town to bristol uk trip wouldent do on anything else , great video but iam ktm fan boy apart from the orange👍

[@GregVillalobos]

What a trip! Enjoy :-)

[@bearfoot6910]

I just repaired the snapped bolt on my side stand as well. I just had it on the stand in the garage, and I hurt a pop. The next thing I know the bike is on the ground. The bolt just snapped off inside the housing. I drilled it out and was able to back it out with a back out bit. I got lucky. fixed it for about $5

[@GregVillalobos]

That's a lucky fix. Good job.

[@teddylott]

Any new videos planned for 2024 Greg?

[@cooper1258]

See if you can get into the ABR Festival next year with it! Sadly not now

[@GregVillalobos]

Yeah I saw that about the pillion pegs. I may try and sneak in and see what happens.

[@ROIBR]

Can u please tell me the tyres front and back again?! Cheers

[@distilledfreedom1840]

Rear is the Motoz Extreme hybrid, front is the Tractionator

[@williamrae9954]

Swingarm....looks like the one on my Husaberg FE390,phone Hills Salvage,they were breaking a Husaberg(the swingarms for some Husabergs were made 5mins from here in Dalry,Ayrshire,but that might have been pre-KTM?),and if they still have one(Hills),take your one with you and compare notes. There's been a FE390 on eBay for yonks,with a brand new swingarm ,no idea why he changed it,that might be another source? Clutch...time for a Rekluse? ;) Same here with my 13yr old 'Berg,dunno wether to keep it or trade the Tracer7 and sell the 'Berg for a brand new Gas Gas ES 700,which is a steal at £8 Grand,i was building it for the Albanian TET, just dog slow for the road work(going by van to Brindisi, Italy,only 1 hard and 2 easy days drive from Glasgow,if you use the boats-Spain/Italy). Keep the boats in mind,now that carnet rules have been relaxed...the Black Sea,Greece,Turkey,etc beckon! :)

[@GregVillalobos]

Good idea about the salvage stuff

[@timharris258]

Hi Greg! Is the hard starting issue present all of the time? I noticed that when cold my 501 would need a little bit of starter work to get going but once it started once it would start perfectly everytime after. I changed fuel filters, it did not change, forum suggests that the battery is a bit weak for the engine and struggles a bit when it is cold. If the issue is happening more with the engine being hot I would agree that the valves might be out! Sick video as always, would love to turn my bike into a full light adv bike instead of half assing it and traveling on my stock Enduro 😁

[@GregVillalobos]

Thanks Tim! I think it may be partly the battery but it does get harder to start when hot so pretty sure the valves need attention.

[@ronanrogers4127]

Long time no see Greg, all good? How’d the rebuild go?

[@GregVillalobos]

Bike is now on Piston 2 and about 30,000km. Running well!

[@bryansuperduke1290r]

Juts start it in first gear to pull away and get into neutral and coast to a stop, turn bike off, put into first gear and start again to pull away.

[@GregVillalobos]

Thanks for the tip

[@bearfoot6910]

can you tell me the tire brand again? I could quite catch the make.

[@ronanrogers4127]

Motoz, an Australian company, their designs and R&D, but made in Thailand…Motoz Rallz on the front he said. Great tyres, I used them on my 1290SA

[@GregVillalobos]

Yup Motoz Tyres

[@NK-dl2nc]

Bike looks great Greg. I made my own light similar yours for my CCM 644. Worked great. Just sold it to fund a tenere world raid and really wishing I could have kept it as I had built it into an ideal tet bike with large tank etc.

[@GregVillalobos]

I'm sure you will have fun on the World Raid. Especially on the road sections! :-)

[@williamrae9954]

Ha...i'm building the very thing(CCM 644) with the same parts....Acerbis 25litre tank and seat off a early '90's Suzuki DR650 on a custom subframe...my Sth American bike!

[@steveh545]

my new PR7, right out of the box, had the same clutch problems. i bled, rebled, rebled. it would work, then no clutch, then 20 min later come back. I finally put an oberon slave on, and it think it's working. Life has kept me from riding the past 3 mos, so not 100% sure it's working. Hopefully in Aug, if the temp gets below 100, i'll hit the roads to see.

[@GregVillalobos]

My PR7 clutch was OK. It's a shame this happened to you :-(

[@networker-wildrats]

Steve - did the Oberon work?

[@danwood4750]

@Greg'theClutch'Villalobos 🤣 you should try x-trig PHDS bar mounts. Great for reducing the vibrations into your hands. Not cheap, but worth the investment and a must for long runs in my mind.

[@acp2446]

Great video ! It’s a shame, I have an (almost new) 2018 ktm 250 freeride swingarm at home that I will happily give you, only I’m not sure if it’s a perfect fit

[@GregVillalobos]

Oh wow! That's generous. Do you have a part number? 🙏

[@acp2446]

@@GregVillalobos I'm afraid not, it was given to me by my cousin who had the bike (but broke the motor) and he gave it to me among a lot of spare parts thinking I had the same bike (I had an EXC 250). I won't be doing anything with it any time soon, I'm based in south of France should you swing by. I'll try to have a look at it to see if I can spot the part number just in case.

[@danielhahn55]

Hi Greg, This is incredible, I love the evolution of your bike! My 701 Enduro is probably taking a similar route, although a bit more comfort-oriented (Navigation Tower and high windscreen, mostly). However, I wanted to ask about the service intervals of your engine. were they an issue? I was talked out of using a 450 EXC as starting point, since the engine service intervals would be so tight.

[@TheIdlesurfer]

Good call on the 701. Mine has a Nomad tower and a Seat Concepts seat. My 2016 has been all over the TET. I also have a 350 FE. Brilliant little bike but for mixed terrain, with road miles, the 701 is my weapon of choice.

[@danielhahn55]

@@TheIdlesurfer hah that's exactly the same equipment I chose. Nomad Tower and Seat Concepts seat. I'm currently modifying it, very curious about the bike after the transformation :D

[@GregVillalobos]

Sounds like a great build!

[@TheIdlesurfer]

@@danielhahn55 Those 2 changes transform the bike from an overweight, over powered trail bike to a brilliant light adventure bike. I've got Kriega ADV paniers and frames which mean I don't have to worry about the lack of subframe for a big tour or when you need to carry fuel. Be careful how much you put on any rear rack. The tank/subframe does fail. My 701 has gone everywhere I've pointed her, and I am a distinctly mediocre rider. And whatever you do, don't get a Rekluse clutch for the 701. It ruins engine braking. The Rekluse in my 350, excellent. Horrible in the 701. Top tip. Keep a close eye on the oil, and top up little and often. My friend overfilled his 2018 701 and it stopped his bike dead. You've made a good call, brother, on the 701 but it has its faults, but as an all round bike, it takes some beating.

[@danielhahn55]

@@TheIdlesurfer thank you so much for that information!! I planned using the same rack, seems to be the proper kit to buy :D also I've made good experience with Kriega in the past. Thanks for the tips! I'll keep them in mind!

[@PaulFoxton]

Curious whether you've lowered it Greg, since I think we're about the same height? (5'7). If not how do you find the height?

[@GregVillalobos]

Yes it's been lowered using an Australian kit that puts spacers in the rear suspension and on the front forks. Dropped by about 20mm I think. It's still tall but better and you get used to riding it. I don't have any issues at all now.

[@PaulFoxton]

@@GregVillalobos Cool thanks. Very tempted to try one of these or a 500. Picking up my DR650 stops being funny after the first couple of times.

[@Lowdown13blues]

Hi Greg I just got one question and one question only, why never a 500 ? Thank you P.S: if you mention it in one your vids just point me where to look at

[@distilledfreedom1840]

Agreed. These 12-16 bikes are the tits. I love my 15' 501 just as much. So glad I didn't sell. Oh and no, that is the only sizable tank I could find. I have the same one. I think it looks just fine. 4.1 gallons is pretty nice. There is an IMS tank part number 112423-N2 that also fits, however it's only 3.1 gallons and you need some different hardware to utilize it. The plus with the IMS is the brass threaded inserts.

[@Moto_Yelt]

How do you cope with oil changes on such a big trip?

[@GregVillalobos]

Oil change roughly every 30hrs. Sometime a bit more. Happy to do 2000 miles on a trip between changes which gets you pretty far.

[@facatube]

I like the way this light looks moderm vintage mix. Sure you are going to notice the weight lost compared with your PR7 ;-)

[@GregVillalobos]

Yup it's certainly easier to pick up

[@nu77byte49]

Is a cush hub required as your hitting abit of tar ??

[@Memacemachine]

From my personal experience: I have been riding on different EXC bikes for more than 1000 hours of ADV riding, and I have noticed a significant improvement in the durability of the chain, sprockets and gears. I think the use of a crushdrive is the key factor, as it reduces the stress and wear on the drivetrain components. The crushdrive also helps to smooth out the power delivery and prevent wheel hop. The EXC bikes are amazing machines, and the crushdrive makes them even better.

[@swinp22]

What cc are all the bikes (apart from your KTM 450 ;)... )

[@GregVillalobos]

250, 300, 310, 450, 690 :-)

[@CinntSaile]

Would you get another PR7?

[@GregVillalobos]

I feel that I have told the PR7 story so probably not.

[@EdwardBondellio]

Hi Greg What sprocket combination are you using?

[@GregVillalobos]

48 / 13... I think!

[@triskelworkshop2855]

did you say 60K or 16K on the bike ?

[@GregVillalobos]

At the time 16k

[@facatube]

If you ´llvisit again Las Bardenas notice me I can show you some local tracks ;-)

[@GregVillalobos]

Thanks!

[@Durkan34]

Looks ace . Like a baby desert sled…

[@GregVillalobos]

Thanks! I'd love to take this to the desert :-)

[@verenchook]

I have a dream to build an afordable ktm 450 dakar.

[@ogasi1798]

i have a phrase for all to consider - i would rather suffer a little on road than a lot off road: The 500 i own makes the off road very very, very enjoyable, roads are meh on it especially with metz 360 but who cares about roads anyway - they suck. If you prefer the phrase in reverse then good luck to ya

[@GregVillalobos]

Yup - choose your compromise!

[@cooper1258]

Enjoyed the the video. I have all the same issues with my KTM 400 EXC. Love it on the lanes. I really should by a CRF300L for practicality but can't bring myself to do it. Too bland and reliable 🤪🤣

[@GregVillalobos]

Head and heart

[@dediarsyad541]

MASTER MOTOR .............

[@rvstechnologyuk3464]

Great video as always!!! Got me thinking that's for sure. Try some of the RVS as it's awesome for the KTM Internals. PM me and I can send some up.

[@GregVillalobos]

Thanks, I'll take a look.

[@jonathantee1880]

Haha - I can relate to losing the hard earned mud 🤣

[@GregVillalobos]

So annoying!

[@mikeisland7382]

Clearly you guys don't live where there's sticky mud. I wish it came off with a little rain.