School me on the KTM 200 engine

Tommywallbanger 10/2/2020 10:50am
10/2/2020 10:50am
Frodad78 wrote:
I'm rebuilding a 97 KDX200 and I can't wait to get it in the woods!
Tommywallbanger wrote:
Hey man I've heard from a few people when I ask them what their favorite bike has been. The KDX 200. I can't believe I've never...
Hey man I've heard from a few people when I ask them what their favorite bike has been. The KDX 200. I can't believe I've never had one as I love 200 cc 2 strokes and I've had more Kawasaki's than any other bike.
TeamGreen wrote:
My '91 KDX was actually fun to race at MX races...no shit.

You'll have to add me to that list of your's.
Back in like 1985 when I had only been riding for like a year I had a 1984 KX 80. Great bike, one of my favorites. I had a buddy who had a KDX 80 and there wasn't anything I could do on my bike he couldn't do on his KDX. There were a bunch of times when he did something like climb a super steep hill and I was almost shamed into doing it because if he could do it on a KDX I figured I could make it on my KX. He was a good rider and it made me a better rider. But that was the only KDX I ever rode. It actually handled better than mine probably because it was a little smaller. His bike felt like mine but it felt like I was in a gear lower if that makes any sense. That little KDX had plenty of power too.
FWYT
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FWYT 10/2/2020 1:35pm
10/2/2020 1:35pm
Working on my 2004 200 at the moment, as a matter of fact! Love this bike!

Wallbanger, I just run straight distilled with water wetter.
1
Tommywallbanger 10/2/2020 1:52pm
10/2/2020 1:52pm
FWYT wrote:
Working on my 2004 200 at the moment, as a matter of fact! Love this bike!

Wallbanger, I just run straight distilled with water wetter.
Wow well I guess you guys really don't have to worry about antifreeze in CA. Where do you ride out there? Dessert? When I was in SD many years ago visiting friends their neighbor had a CR 500 with paddle tires, dessert beast. What model is your 200 an SX? I think I found some coolant that is pretty similar to Motorex M 3. It's Peak Final Charge Global Extended Life. I don't race so being ethylene glycol based doesn't affect me. I just haven't heard from any body if that stuff is OK to use. I'll buy the M 3 if it really does something above and beyond other generic coolant. I keep hearing things like the wrong coolant can cause sludge in the system, it can corrode seals in the water pump and corrode the aluminum. I don't understand what ethylene glycol even is but I'll spend the extra money on M 3 to ensure my bike doesn't fail on me for something stupid like a water pump seal.
blackfriday 10/2/2020 8:18pm
10/2/2020 8:18pm
In 2001, Sellards rode a 200 SX for Red Bull KTM at the US Open against 250s and 450s --- er "426s." :D
He definitely qualified for the second night's main event; I don't remember the first night though.

The Shop

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Tommywallbanger 10/2/2020 8:27pm
10/2/2020 8:27pm
That must have been tough against 250 2 strokes and 400 cc 4 strokes. Hey I guess with the right rider anything's possible. A tight track would help too. The 200 had the great engine but it didn't handle well so there wasn't much of a trade-off between power and handling. The pds suspension held it back and it was hard to control. I felt like I could only take certain lines on that bike. When you would stuff it into a corner no matter how low you were it always wanted to stand up and high side around a turn. I got some triple clamps with a different offset and that helped but it did not solve its handling woes. Yeah the best part of that bike by far is its engine. My first one the 03 had an FMF fatty and that's the one I liked. The one I have now has a pro circuit pipe which is okay too.
resetjet
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resetjet 10/3/2020 5:51am
10/3/2020 5:51am
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx. Flat land a jump and you run into a wall of compression. Great trail bike though. I have two!!!
Tommywallbanger 10/3/2020 10:11am
10/3/2020 10:11am
resetjet wrote:
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx...
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx. Flat land a jump and you run into a wall of compression. Great trail bike though. I have two!!!
I couldn't agree with you more on that assessment my man. Both an the engine and the handling. I've had 2 as well. I had the 03 with an FMF Fatty pipe and the one I have now is an 04 with a Pro Circuit pipe. On the '03 I got a set of after market triple clamps and it helped the handling a little bit but that frame just had bad geometry. Every time I would go into a turn it wanted to stand up. It resisted you when you would lean it over and it always felt like it was falling over like a top. Not a well balanced bike. Great engine though. I always called it the "Widow maker." It finally bit me in 2017 and I broke my hand on it.I remember the 1st time I rode it though and went wide open I couldn't believe the top end.

What kind of pipes do you run on them? I see those Scalvini pipes too that look really cool. I just got finished and I mean like this week, putting the 04 200 SX engine into a 2015 KTM 150 SX chassis. I had ProTune do the KYB SSS conversion to the forks and got the correct spring for my 200 pound ass so it should rip. I haven't ridden it yet as I'm recovering from a surgery but man am I itching to ride it. I'll go break it in in a few days. I just did a new top end so I have to go easy at first anyway and I can't wait to see how the forks work.

Yeah I love those 200 engines, you can wind them out or lug them around and they always start on the 1st or 2nd kick. I was considering buying a Beta 200 RR and tried one at the demo days last year. Real nice bike but being I had the 200 SX engine and the conversion to the 150 frame was relatively easy, I went that route.
Tommywallbanger 10/3/2020 10:19am
10/3/2020 10:19am
resetjet wrote:
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx...
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx. Flat land a jump and you run into a wall of compression. Great trail bike though. I have two!!!
Do you even use anti freeze in your engine coolant living in FL? The reason I ask is I'm in NJ and do need anti freeze and I'm just trying to figure out what guys are using these days. Also, I'm trying to avoid paying $40 to buy 2 liters of Motorex M3 to get the 1.2 liters I need to fill my bike. Someone in another forum told me that Peak Final Charge Global Extended Life coolant will work just as well but at 1/3rd the price. My bike calls for silicate-free ethylene glycol based coolant.
Anybody out there using something cheaper than the M3? Let me know Thanks
Aceofspades 10/3/2020 7:40pm
10/3/2020 7:40pm Edited Date/Time 10/3/2020 7:43pm
Follow up to my original post from 2016: I ended up buying a leftover 14 Rmz450 for $5100 out the door, kept it about six months, sold it for half what I paid (with about 10 hours on the engine timer) and two weeks later bought an 08 RM250 lol. Rode the RM about two months and then sold it and haven’t bought anything else. My back problem flared up and I gave up, plus I just had another baby at age 48 so I’m going to get him a bike instead lol. On a side note: that 08 RM250 I will regret selling til the day I die!!! Oh my god, what a great, great, great bike and wonderful, punchy power band. The best two stroke bike I’ve ever ridden and I’ll never find another one🤷‍♂️
FreshTopEnd
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FreshTopEnd 10/3/2020 8:05pm
10/3/2020 8:05pm
200's are one of the great engines. I think they drop into the early linkage 125s (maybe 11-13) and that's a nice bike.

I built a fun one, but really can't ride and let it go. I do have a stock clean 200 SX pipe from the 003-4 I believe f anyone is interested. I'll not be using it and can use the space for Maico bits.
Tommywallbanger 10/3/2020 9:31pm
10/3/2020 9:31pm
FreshTopEnd wrote:
200's are one of the great engines. I think they drop into the early linkage 125s (maybe 11-13) and that's a nice bike. I built a...
200's are one of the great engines. I think they drop into the early linkage 125s (maybe 11-13) and that's a nice bike.

I built a fun one, but really can't ride and let it go. I do have a stock clean 200 SX pipe from the 003-4 I believe f anyone is interested. I'll not be using it and can use the space for Maico bits.
The 200 SX engine can be put into a 125 or 150 SX up until the 2015 model. 2012 to 2015 if you want the rear linkage. They changed everything up for 2016.
I've had 2 KTM 200 SX's, both were used and both had after market pipes but from what I have heard, the stock pipes were highly sought after. The only problem is that they are super thin and dent easily. If you can't find a buyer on the forums try eBay. It more people will see it. I hear people rave about the stock pipes and the Scalvini one.
resetjet
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resetjet 10/4/2020 5:46am
10/4/2020 5:46am
resetjet wrote:
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx...
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx. Flat land a jump and you run into a wall of compression. Great trail bike though. I have two!!!
Tommywallbanger wrote:
I couldn't agree with you more on that assessment my man. Both an the engine and the handling. I've had 2 as well. I had the...
I couldn't agree with you more on that assessment my man. Both an the engine and the handling. I've had 2 as well. I had the 03 with an FMF Fatty pipe and the one I have now is an 04 with a Pro Circuit pipe. On the '03 I got a set of after market triple clamps and it helped the handling a little bit but that frame just had bad geometry. Every time I would go into a turn it wanted to stand up. It resisted you when you would lean it over and it always felt like it was falling over like a top. Not a well balanced bike. Great engine though. I always called it the "Widow maker." It finally bit me in 2017 and I broke my hand on it.I remember the 1st time I rode it though and went wide open I couldn't believe the top end.

What kind of pipes do you run on them? I see those Scalvini pipes too that look really cool. I just got finished and I mean like this week, putting the 04 200 SX engine into a 2015 KTM 150 SX chassis. I had ProTune do the KYB SSS conversion to the forks and got the correct spring for my 200 pound ass so it should rip. I haven't ridden it yet as I'm recovering from a surgery but man am I itching to ride it. I'll go break it in in a few days. I just did a new top end so I have to go easy at first anyway and I can't wait to see how the forks work.

Yeah I love those 200 engines, you can wind them out or lug them around and they always start on the 1st or 2nd kick. I was considering buying a Beta 200 RR and tried one at the demo days last year. Real nice bike but being I had the 200 SX engine and the conversion to the 150 frame was relatively easy, I went that route.
Ive tried all the pipes. For mx the stock pipe is best. Thats a nice bike you are building. I think you can add estart to it. My friend just did a 15 husky conversion......great bike.
resetjet
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resetjet 10/4/2020 5:49am
10/4/2020 5:49am
resetjet wrote:
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx...
The 200sx motor was the bomb. A factory 125 in stock form. The chassis however is freakin terrible. Any non linkage bike is terrible for mx. Flat land a jump and you run into a wall of compression. Great trail bike though. I have two!!!
Tommywallbanger wrote:
Do you even use anti freeze in your engine coolant living in FL? The reason I ask is I'm in NJ and do need anti freeze...
Do you even use anti freeze in your engine coolant living in FL? The reason I ask is I'm in NJ and do need anti freeze and I'm just trying to figure out what guys are using these days. Also, I'm trying to avoid paying $40 to buy 2 liters of Motorex M3 to get the 1.2 liters I need to fill my bike. Someone in another forum told me that Peak Final Charge Global Extended Life coolant will work just as well but at 1/3rd the price. My bike calls for silicate-free ethylene glycol based coolant.
Anybody out there using something cheaper than the M3? Let me know Thanks
I have just been using peak or prestone for years with no issues $14 a gallon. 200’s dont overheat. Rotella for the oil.
dcg141
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dcg141 10/4/2020 6:38am
10/4/2020 6:38am
Had a customer put a 125 SX ignition and 38 mm carb on one once and that thing was amazing.
Tommywallbanger 10/4/2020 7:16am
10/4/2020 7:16am
dcg141 wrote:
Had a customer put a 125 SX ignition and 38 mm carb on one once and that thing was amazing.
What bike did he put that pipe and ignition on? The 150 Husky? I still have the 150 SX pipe and CDI box and may hook them up to the 200 SX engine one day just to see how it performs.
Tommywallbanger 10/4/2020 7:29am
10/4/2020 7:29am
resetjet wrote:
I have just been using peak or prestone for years with no issues $14 a gallon. 200’s dont overheat. Rotella for the oil.
I use Motorex Top Speed 15W-50 synthetic and since I wasn't sure about the coolant I broke down and bought the Motorex M 3 coolant. That's what KTM recommends but that stuff is a rip off. Next time I'll use Prestone. I'm researching this Peak final charge global extended life coolant. $17 a gallon vs $17 per liter. I didn't want to take any chances and I love my bike enough that it wasn't worth risking putting something in it that might damage seals or sludge up or cause bigger problems.
dcg141
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dcg141 10/4/2020 8:08am
10/4/2020 8:08am
dcg141 wrote:
Had a customer put a 125 SX ignition and 38 mm carb on one once and that thing was amazing.
Tommywallbanger wrote:
What bike did he put that pipe and ignition on? The 150 Husky? I still have the 150 SX pipe and CDI box and may hook...
What bike did he put that pipe and ignition on? The 150 Husky? I still have the 150 SX pipe and CDI box and may hook them up to the 200 SX engine one day just to see how it performs.
It was on a 09 200 XC. Last year they made that bike. He put the ignition and 38 mm carb from the same year 125 SX. The 200 then was running a 36 to make it more of a bottom to mid bike. Ran a FMF Fatty and shorty silencer.
resetjet
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resetjet 10/4/2020 6:04pm
10/4/2020 6:04pm
resetjet wrote:
I have just been using peak or prestone for years with no issues $14 a gallon. 200’s dont overheat. Rotella for the oil.
Tommywallbanger wrote:
I use Motorex Top Speed 15W-50 synthetic and since I wasn't sure about the coolant I broke down and bought the Motorex M 3 coolant. That's...
I use Motorex Top Speed 15W-50 synthetic and since I wasn't sure about the coolant I broke down and bought the Motorex M 3 coolant. That's what KTM recommends but that stuff is a rip off. Next time I'll use Prestone. I'm researching this Peak final charge global extended life coolant. $17 a gallon vs $17 per liter. I didn't want to take any chances and I love my bike enough that it wasn't worth risking putting something in it that might damage seals or sludge up or cause bigger problems.
No, i know literally a hundred guys that do the same...no issues.

Pit Row

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Tommywallbanger 10/7/2020 9:02am
10/7/2020 9:02am
Got it done and took it out to break it in yesterday. What a difference the extra 50 cc's makes. Much easier to pull the front end up over stuff. I still have to dial in the suspension, put a set of handle bar risers on it, and true up the front rim a little bit. I'm real happy with the bike now. I doubt I'll ever get rid of this. Yeah it's a keeper. Lucky for me the 200 engine fits right into the 150 frame.
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Tommywallbanger 10/6/2021 10:09pm
10/6/2021 10:09pm
Tommywallbanger wrote:
I just got done a custom build and I know it was not that hard to pull off especially after some of the ones I've seen...
I just got done a custom build and I know it was not that hard to pull off especially after some of the ones I've seen online and in the forums. Hard or not this bike is hopefully going to be everything I've wanted in a bike. I had a 2003 and then a 2004 KTM 200 SX. I absolutely love the engine but they didn't handle so well. In March I bought a 2015 KTM 150 SX since the 200 SX engine would fit in that frame. I just got done putting the 200 SX engine in the 150 frame. I haven't even rode it yet. It's only been started to flush out the old coolant with distilled water. So that brings me to my question: what coolant are you guys running in your KTM 200 engines. My manual says silicate-free ethylene glycol based coolant. The only one I can find is the Motorex M3 and M5 stuff and that's $28 a liter and I need 1.2 liters to fill up my system. There has to be something else out there. I don't want to use Engine Ice because it's not ethylene glycol based. I don't want to damage any water pump seals or radiator welds. I'm just curious what you guys are using in your bikes. I understand most race tracks don't allow ethylene glycol based coolant use but I don't race and I don't want to flush my coolant every year.
Toyota and Honda both make a silicate free ethylene glycol based coolant but I want to check here first before buying something. Thanks guys.
Update on my KTM 150 SX with 200 SX engine: It rips. I love this bike and I knew I would. I didn't like the front forks so I sent them out to Corey at ProTune and that made it work just right. I noticed a week ago that the exhaust O Ring was ripped and coming off the pipe. I think it's because the Pro Circuit pipe I have on it is so wide that it is pushing against the radiator hose from the water pump. It's squished in between the pipe and frame and I think it's puts the pipe out of alignment a little bit. I think I'm going to get a slightly longer piece of radiator hose so I can go out in front of the pipe and frame a little bit so the pipe can fall into the frame closer and be more seated correctly. other than that no problems with it. It has plenty of usable power. I've read in this forum comments where guys have put KDX 200 engines into KX 125 frames. That might be a fun build but I don't think the KDX engine is as good as the 200 SX engine but if I had the time and the parts just maybe. I really love 200 cc 2 stroke engines.
3
Orange
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Orange 10/7/2021 3:35am
10/7/2021 3:35am
Tommywallbanger wrote:
Update on my KTM 150 SX with 200 SX engine: It rips. I love this bike and I knew I would. I didn't like the front...
Update on my KTM 150 SX with 200 SX engine: It rips. I love this bike and I knew I would. I didn't like the front forks so I sent them out to Corey at ProTune and that made it work just right. I noticed a week ago that the exhaust O Ring was ripped and coming off the pipe. I think it's because the Pro Circuit pipe I have on it is so wide that it is pushing against the radiator hose from the water pump. It's squished in between the pipe and frame and I think it's puts the pipe out of alignment a little bit. I think I'm going to get a slightly longer piece of radiator hose so I can go out in front of the pipe and frame a little bit so the pipe can fall into the frame closer and be more seated correctly. other than that no problems with it. It has plenty of usable power. I've read in this forum comments where guys have put KDX 200 engines into KX 125 frames. That might be a fun build but I don't think the KDX engine is as good as the 200 SX engine but if I had the time and the parts just maybe. I really love 200 cc 2 stroke engines.
A buddy did that conversion. 99 KDX 200 in a 99KX 125 frame. After several mods the engine isn't even close to what my 200sx engines were.
Falcon
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Falcon 10/14/2021 8:47am
10/14/2021 8:47am
resetjet wrote:
I have just been using peak or prestone for years with no issues $14 a gallon. 200’s dont overheat. Rotella for the oil.
Tommywallbanger wrote:
I use Motorex Top Speed 15W-50 synthetic and since I wasn't sure about the coolant I broke down and bought the Motorex M 3 coolant. That's...
I use Motorex Top Speed 15W-50 synthetic and since I wasn't sure about the coolant I broke down and bought the Motorex M 3 coolant. That's what KTM recommends but that stuff is a rip off. Next time I'll use Prestone. I'm researching this Peak final charge global extended life coolant. $17 a gallon vs $17 per liter. I didn't want to take any chances and I love my bike enough that it wasn't worth risking putting something in it that might damage seals or sludge up or cause bigger problems.
Good on you for following the factory recommendations.

FYI, Ethylene Glycol is the basis for most "old-school" coolant/antifreeze products. It is the bright green stuff we commonly think of when using coolant. Your only concern with Peak, Prestone, or other "regular" coolants would be the silicate content. I'm not sure if those Walmart brands have any silica in them - it should be on the label, though.
Spergen
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Spergen 10/14/2021 12:47pm
10/14/2021 12:47pm
Funny this thread should come up, I have a 16 exc 200 and love that bike for hare & hounds racing, thicker base gasket, fatty pipe and adjusted the PV. Never lets me down on the starts or on rough twisty bits, just lacking on the open sections where bigger bikes get past then hold me up in the woods etc!

My dilemma now is do I go tpi 250 or try a beta 200? Hmmmm decisions.......
FreshTopEnd
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FreshTopEnd 10/14/2021 2:26pm
10/14/2021 2:26pm
Still have that stock 200SX pipe if anyone is interested. And I love that bike! Thanks for the update
Spergen
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Spergen 10/14/2021 3:05pm
10/14/2021 3:05pm
FreshTopEnd wrote:
Still have that stock 200SX pipe if anyone is interested. And I love that bike! Thanks for the update
I can't believe no one took you up on that all those years ago when you first posted obout it. Best pipe for that bike and like rocking horse poop
Tommywallbanger 10/14/2021 5:05pm
10/14/2021 5:05pm
resetjet wrote:
I have just been using peak or prestone for years with no issues $14 a gallon. 200’s dont overheat. Rotella for the oil.
Tommywallbanger wrote:
I use Motorex Top Speed 15W-50 synthetic and since I wasn't sure about the coolant I broke down and bought the Motorex M 3 coolant. That's...
I use Motorex Top Speed 15W-50 synthetic and since I wasn't sure about the coolant I broke down and bought the Motorex M 3 coolant. That's what KTM recommends but that stuff is a rip off. Next time I'll use Prestone. I'm researching this Peak final charge global extended life coolant. $17 a gallon vs $17 per liter. I didn't want to take any chances and I love my bike enough that it wasn't worth risking putting something in it that might damage seals or sludge up or cause bigger problems.
Falcon wrote:
Good on you for following the factory recommendations. FYI, Ethylene Glycol is the basis for most "old-school" coolant/antifreeze products. It is the bright green stuff we...
Good on you for following the factory recommendations.

FYI, Ethylene Glycol is the basis for most "old-school" coolant/antifreeze products. It is the bright green stuff we commonly think of when using coolant. Your only concern with Peak, Prestone, or other "regular" coolants would be the silicate content. I'm not sure if those Walmart brands have any silica in them - it should be on the label, though.
Yeah I was worried about the silicate content so I went and ordered the expensive stuff (Motorex M3.) It just wasn't worth the risk of cheaping out and causing a water pump problem.
Elliot
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Elliot 10/14/2021 7:07pm
10/14/2021 7:07pm Edited Date/Time 10/14/2021 7:10pm
For me a 200 is the perfect displacement for riding Hare & Hounds in a usually muddy England.

I used to have a couple of KDX 200s but had this '03 EXC from new and only sold it last year when I hung up my Alpine Stars.

The motor is totally bullet proof and I only had 2 new top ends in the 17 years I had it. Apart from an FMF pipe & silencer the only engine mod was a Steahly flywheel weight for tight woods stuff but it didn't really need it as the stock torque was surprisingly good.





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Spergen
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Spergen 10/15/2021 5:49am
10/15/2021 5:49am
Elliot wrote:
For me a 200 is the perfect displacement for riding Hare & Hounds in a usually muddy England. I used to have a couple of KDX...
For me a 200 is the perfect displacement for riding Hare & Hounds in a usually muddy England.

I used to have a couple of KDX 200s but had this '03 EXC from new and only sold it last year when I hung up my Alpine Stars.

The motor is totally bullet proof and I only had 2 new top ends in the 17 years I had it. Apart from an FMF pipe & silencer the only engine mod was a Steahly flywheel weight for tight woods stuff but it didn't really need it as the stock torque was surprisingly good.





I see you were a clubman so no slouch, how did the bottom end and gearbox hold out? Still In 2 minds about getting a new one to replace my 16 exc, up to 150hours now, only use it for race days though.

Pity to give up, 45 now so hoping for 10 more years, don't suppose your anywhere near Lincolnshire? Lincolnshire enduro club is just for beginners and old fat men, loads of blue pill crew still riding as the tracks are easy but still good
Elliot
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Elliot 10/15/2021 6:31am
10/15/2021 6:31am
I don't think the bottom end & gearbox ever needed touching. Fortunately I only live a few miles from Matt Norris so he took care of the engine for me http://www.mattnorrisengineering.com/

That guy used to build engines for Max Anstie so if he says the bottom end's fine, then it is.

I raced about a dozen times a season. I used to be fairly good but when I past 50 I struggled to finish in the top half of the field although I carried on till I was 60. I've been riding dirt bikes since I was 16 so I've not missed out lol.

I used to race mainly in Portsmouth and Blewbury (Oxfordshire) which was a blast.





Tommywallbanger 10/15/2021 6:36am
10/15/2021 6:36am
FreshTopEnd wrote:
Still have that stock 200SX pipe if anyone is interested. And I love that bike! Thanks for the update
How much you want for that pipe? I also can't believe you still have it. I don't think a lot of people are reading this forum though. We're a pretty much a special interest group. I've heard the stock pipe is great but it dents easily. I plan on keeping my bike a LONG time and this just might be a part I should stock. The FMF fatty is a nice pipe on this bike too, my 2003 had one. My 2004 has a Pro Circuit Platinum and from what i remember I preferred the Fatty. I wonder if the jetting would be the same for the stock pipe and Pro Circuit Platinum.

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