KTM 200 Build finished.

FreshTopEnd
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Edited Date/Time 2/18/2014 9:18pm
Okay, it's definitely not a Newman refresh of a fresh bike, and I work slower than Joe, but here's some before and after shots of the 08 200XC I picked up last summer. I'd been looking for a long time for an XC, the close ratio box, and finally found one. t was pretty beat, not well-cared for. Went through it, fresh top end, cleaned up the power valve (nasty bit, that) PC works pipe for the 03-04 200SX (don't care for the nickeled PC and FMF pipes), got a killer deal on a new Ohlins TTX for $500 (there went the orange frame), new seat, SX tank, new plastic and BNG. Still have a few things to add, and have some different CDIs to play with if it gets that far. Have an Acerbis big tank if I can make it back out to the desert later in the spring.

Will be trying it out at a mini GNCC type track tomorrow, easy going, and I'll find out if I even have some good trail riding left in the bod. Track riding has been out since the 90's, and I've been feeling a lot slower in the last year, so we'll see. If the jig is up, it'll go for sale and I'll settle for tinkering on the old stuff. In any event, it was a lot of fun to work on getting it cleaned up. The 200's are one of the best dirt bikes ever made; pure blast!

Before:





After:



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JW381
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1/18/2013 3:50pm
Must be a whole boat load of fun!
DrSweden
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1/18/2013 3:52pm Edited Date/Time 1/18/2013 4:09pm
Good work! Nothing to be ashamed of.

Newman kind of kills it for everyone of us, I think he should be clicked for destroying the collective self confidence! Grinning
mxb2
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1/18/2013 3:55pm
Nice build. Hope red bull does not see the graphics. Lol. They say you need to be a red bullTongue athlete to have them.and the haters will say your a poser who should use all oem stuffTongue

The Shop

malachi177
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1/18/2013 4:07pm
Sweet looking bike! Looks alot better. That motor is supposed to be awesome.
newmann
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1/18/2013 4:12pm
Stop picking on me. Angry

And keep picking on the nickle pipe people. One day when you live in a high humidity area and have a dozen of those raw pipes to maintain, those nickle plated ones start making a whole lot more sense.

Looks good FTE, I like the whole 200 idea. One of those "perfect bike" scenarios! But do you understand the legal ramifications of running the Red Bull logo illegally? What will you do when Red Bull confiscates your bike just like they said they could do to my 8 year old sons helmet several years back....Laughing

Ride report please?
newmann
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1/18/2013 4:14pm
Oh and MXB2, cold and rainy here. Damn near flooding actually for a while there. Still no ride on the KTM! Weather looking decent this weekend, just in time for another out of town swim meet...
Frodad78
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1/18/2013 4:28pm
that is awesome, I'd love to spin some laps on that thing.
mxb2
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1/18/2013 5:00pm
newmann wrote:
Oh and MXB2, cold and rainy here. Damn near flooding actually for a while there. Still no ride on the KTM! Weather looking decent this weekend...
Oh and MXB2, cold and rainy here. Damn near flooding actually for a while there. Still no ride on the KTM! Weather looking decent this weekend, just in time for another out of town swim meet...
10-4 keep us posted. I want one. Braap
Motoxtombo
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1/18/2013 5:27pm
Nice looking bike Mike, I bought a 2013 250SX a few months ago,Its looks pretty plain compared to your bike.i might have to dress it up a little. Smile
yak651
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1/18/2013 5:36pm
Looks nice, wonder why ktm stopped making the 200? I would like to try one someday
FreshTopEnd
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1/18/2013 5:56pm
Thanks all!

They still make the 200, but just in the wide ratio box. It's actually e-start now. There are people modding 150's with 200 top ends to get the close ration six speed. The 125-200 are all based on the same bottom end cases.
Derpin' DJ
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1/18/2013 6:17pm
Ha, I always type in ration instead of ratio.

I don't think the 200's are electric start. My brother bought a 2012 not long ago and it's kickstart only
1/18/2013 7:01pm
Thanks all! They still make the 200, but just in the wide ratio box. It's actually e-start now. There are people modding 150's with 200 top...
Thanks all!

They still make the 200, but just in the wide ratio box. It's actually e-start now. There are people modding 150's with 200 top ends to get the close ration six speed. The 125-200 are all based on the same bottom end cases.
I was wondering about the 150 vs the 200 for woods riding. Guess off the floor the 150 is sprung stiffer than the 200?
TX24
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1/18/2013 7:04pm
Derpin' DJ wrote:
Ha, I always type in ration instead of ratio. I don't think the 200's are electric start. My brother bought a 2012 not long ago and...
Ha, I always type in ration instead of ratio.

I don't think the 200's are electric start. My brother bought a 2012 not long ago and it's kickstart only
It can be an aftermarket on the 12's. or maybe it was the 11's.
Denn700
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1/18/2013 7:12pm
That is a good looking bike!!!!
MelonFan123
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1/18/2013 10:01pm
FTE, why did you change the pipe so drastically? The "before" bike had a expansion chamber that curved around like a 250 pipe, whereas the pipe in the "fixed up" version is a straight bend like a traditional 125 pipe? Just wondering the reason for the change
bents
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1/18/2013 10:02pm
Awesome job FTE. Beautiful job.
tobz
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1/18/2013 10:08pm
Welcome to the 200 club. I've had a boatload of fun tinkering with mine. I found for trail riding I enjoy the stock/low end power pipe/exhaust, the sx pipes are like. 125 power, no down low but scream to the moon.

Small adjustments to the power valve timing yield vast results to, much fun playing with that.
tobz
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1/18/2013 10:10pm Edited Date/Time 1/18/2013 10:13pm
FTE, why did you change the pipe so drastically? The "before" bike had a expansion chamber that curved around like a 250 pipe, whereas the pipe...
FTE, why did you change the pipe so drastically? The "before" bike had a expansion chamber that curved around like a 250 pipe, whereas the pipe in the "fixed up" version is a straight bend like a traditional 125 pipe? Just wondering the reason for the change
From the 03/04 sx model, the pipe is more like a 125 shape, all top end. The newer pipes from fmf and pro circuit are like 250's shape, a lot of download torque, since these bikes are used mostly for that type of power. Helluva lot of fun on a track with a 200 with 125 like power

13's are e start only, something that will make me NOT buy another one, I've just got to sneeze on mine to start it.
Olson
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1/18/2013 10:48pm
I was about to say that I have never liked the look of that model but it really looks great in the after picture. The new tank and pipe makes it. The angle of the shock without a link still looks weird, probably even weirder with the öhlins making the shock more visible. If you want an input I would personally cut the seat in the back a little making it line up better with the rear fender. Except for that. Great job!
1/18/2013 11:33pm
This is my 2003 200 EXC (yep, 10 years old and had it from new) though this photo is a couple of years old. I've since added an FMF silencer, steering damper & triple clamp combo and new plastics with Enduro Engineering graphics. The Guts seat is a must as the stock unit that passes as a seat is like a piece of wood.

It's only ever needed one new top end and the motor is unbelievably reliable.

For the kind stuff I do - woods racing in England - it is unbeatable. I often wonder about getting a new one but can't logically justify what I'd gain for shelling out 6000 pounds.except for an electric start button.



1/19/2013 6:46am Edited Date/Time 1/19/2013 6:48am
This is my 2003 200 EXC (yep, 10 years old and had it from new) though this photo is a couple of years old. I've since...
This is my 2003 200 EXC (yep, 10 years old and had it from new) though this photo is a couple of years old. I've since added an FMF silencer, steering damper & triple clamp combo and new plastics with Enduro Engineering graphics. The Guts seat is a must as the stock unit that passes as a seat is like a piece of wood.

It's only ever needed one new top end and the motor is unbelievably reliable.

For the kind stuff I do - woods racing in England - it is unbeatable. I often wonder about getting a new one but can't logically justify what I'd gain for shelling out 6000 pounds.except for an electric start button.



I had a 2000 250sx and never had any motor problems either. The thing just lasted forever. Got a 2003 250sx now and the hit on that engine is just scary. Grinning I don't see a reason to 'upgrade' to a newer model or any other bike.

An updated rearend would look nice on your 200. Smile Should be easy to find a cheap fender, airbox, subfame and seat.
burn1986
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1/19/2013 7:26am
Nice FTE! Man, this would make a hard choice bewtween a 150 and 200. I would think the 150 with a 200 top end would be even more of the perfect bike than the 150. Thanks for creating a new dilema for me!
OldYZRider1
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1/19/2013 7:42am Edited Date/Time 1/19/2013 7:44am
Nice bike, I ride one too! Lightweight, agile with really good power. Very reliable bike too, you can likely get 150hrs on a piston.

I also have a 2004 200SX with a 38mm AIr Stryker carb (nice mod). I think the '08 with its 36mm smaller carb and different pipe performs nearly as good and has a little more bottom end. I put on the shorter silencer from an SX which I felt was an improvement. Its a little louder and may not be the best choice for woods riding. I strictly ride my track with mine. I did alter the gearing. I'm running a 14/44 combo (14/48 is standard). There again for woods riding the 48 maybe a better choice. I put on an SX tank too and switched to a 19" rear rim. I couldn't get the shifter in a position to suit me and put on a longer adjustable Hammerhead unit which solved that issue.

I wish this bike was still available or better yet an updated 200SX but still with a PDS suspension. The XC-W's don't appeal to me either, but I may have to build what I want out of one if I want to stay on a 200. Such is the plight of us two stroke riders nowadays (at least MX riders); not many options left for us and trying to make MX machines out of woods bikes!
1/19/2013 9:20am
Nice bike, I ride one too! Lightweight, agile with really good power. Very reliable bike too, you can likely get 150hrs on a piston. I also...
Nice bike, I ride one too! Lightweight, agile with really good power. Very reliable bike too, you can likely get 150hrs on a piston.

I also have a 2004 200SX with a 38mm AIr Stryker carb (nice mod). I think the '08 with its 36mm smaller carb and different pipe performs nearly as good and has a little more bottom end. I put on the shorter silencer from an SX which I felt was an improvement. Its a little louder and may not be the best choice for woods riding. I strictly ride my track with mine. I did alter the gearing. I'm running a 14/44 combo (14/48 is standard). There again for woods riding the 48 maybe a better choice. I put on an SX tank too and switched to a 19" rear rim. I couldn't get the shifter in a position to suit me and put on a longer adjustable Hammerhead unit which solved that issue.

I wish this bike was still available or better yet an updated 200SX but still with a PDS suspension. The XC-W's don't appeal to me either, but I may have to build what I want out of one if I want to stay on a 200. Such is the plight of us two stroke riders nowadays (at least MX riders); not many options left for us and trying to make MX machines out of woods bikes!
I'm not sure what kind of silencer the 04 SX came with but changing the stock item on mine (03 EXC) was a no brainer. I also added a 9 ounce flywheel weight which smooths the low end I lost with the silencer switch.

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