what size radiator hose for KTM 200 SX

Tommywallbanger
Hey guys I know I can take off the old hose and measure it but I'm just curious if anyone knows the size radiator hose the 2004 KTM 200 SX uses? Every search on the web just returns hose kits and I just want to lengthen one hose.
I put this engine into a 2015 150 SX frame and the bike is awesome. The radiator hose that comes off the water pump is routed right in between the frame and the pipe. In my case it's a Pro Circuit Platinum and it's a real tight fit. It's so tight that the hose pushes the pipe out a little from where it would normally seat itself. The way the pipe bends, pushing it out to the side a little puts the pipe inlet at a slight angle where it meets up the the exhaust port outlet on the engine. I noticed the other day the outer O Ring on the pipe where it goes into the front of the engine has ripped and is starting to come out. I have ordered more O Rings but I want to use a longer piece of radiator hose and route it away from in between the pipe and frame so it will allow the pipe to line up better.
I just want to get some radiator hose ahead of time. I'm guessing that 5/8" hose will work which is roughly 16 mm. I figured this would be the place to come to for an answer. Let me know if anybody has this info. Thanks
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Orange
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Orange 10/7/2021 3:29am
10/7/2021 3:29am Edited Date/Time 10/7/2021 3:30am
We had a similar issue putting a Scalvini setup on our 150sx. A control dent in the pipe solved it. I took a chunk of 1" wood dowel, and made enough gap to clear the hose. This method was recommended by Scalvini. That small dent does not effect performance in any way. I also had a similar issue to you with my 200sx in a 13 frame.

Did you re route that throttle cable yet??
Tommywallbanger 10/7/2021 6:10am
10/7/2021 6:10am
Thanks Orange. A buddy of mine did the same thing but I was hesitant to bend the pipe. Do you heat it up first or just lay it sideways along the pipe and tap on it? I actually wanted to get a KTM 150 SX for the build but had a real hard time finding one. I probably should have just looked for a 2013 125 SX but I wanted to see what a 150 was like. It was under powered. Of course I'm a little over 200 so I wasn't too surprised. I have a theory that you need a cc per pound you weigh when it comes to 2 strokes. 250 MX bikes are just a little too hyper for my liking. I have given thought to getting a YZ 250 and going with a heavy fly wheel weight to calm it down a little. I had an RM 250 in like 1999 but just don't care for the 250 power characteristics. The power is nice....sometimes but whiskey throttle when you get off balance. YZ's are more mellow, at least the 1 I rode. I appreciate the advice buddy. I may contact you in the future for more 200 SX related questions if that's cool. Sorry this post got so long but I can talk dirt bikes all day. I'm 48 years old and I've been riding since I was 10. I grew up with a big gravel pit about 300 or 400 ft from my backyard and I'm addicted. This KTM is the best bike I've ever had. Prior to this my 84 KX 80 was my favorite bike. I had a 2004 kxf 250 and it handled really nice but it kept blowing up. I had thought about throwing a 200SX engine into that frame. I saw on one of the forums that someone did that conversion to the RMF 250. But that involved a lot of fabrication that I wasn't comfortable doing myself. I did reroute my throttle cable and the reason I did was I installed handlebar risers and it was giving me a problem. I'm not sure it's the exact recommended placement but I just rerouted the throttle cable behind the steering stem and down the left side of the frame. My forum buddy told me that the correct routing is along the right hand side of the frame. Maybe this winter. Where do you route yours? I think I'm going to go ahead and use your method of putting a dent in the exhaust pipe to get the clearance I need. That's what my buddy told me to do and he knows his stuff. Maybe you've seen him in these forums. Whenever I look through forum posts I usually come across his comments. He goes by the name Poldies in this forum and he gave me a lot of helpful advice when I was doing my 150/200. Thanks again for the advice. I just recently started filming my rides. I put them up on YouTube. Do a search for Tommywallbanger and you'll see my bike in action. Take care man.
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