Posts
36
Joined
6/28/2018
Location
Russellville, TN
US
Edited Date/Time
5/5/2021 8:32am
Hey guys, I’ve been a long time lurker around here but just joined to post my first build. I’ve always loved seeing you alls build threads and it’s actually what got me back into the sport after about 10 years away while in high school and college. I picked up a couple bike in the last year and none of them fit what I wanted so I went on the search for what I thought I wanted. A couple weeks later I came home with a roller of a KTM 200SX and styrofoam coolers full of parts. This is what we had to start with.
It all appeared to be there and didn’t seem to have and major abuse over the time, but the top end was completely destroyed. It looked like the piston had broke a ring and lodged it in a transformer port before coming to an abrupt halt. Cylinder has about. 1/4” deep gouge, the powervalve flap was damaged and of course the head had taken a beating from loose debris bouncing around inside the engine for some amount of time. The good news was that the crank and rod bearings were as tight as could be. Other than this and some broken plastics the rest of the bike looked pretty good for a base build, so after the first night this is what we were left with.
It all appeared to be there and didn’t seem to have and major abuse over the time, but the top end was completely destroyed. It looked like the piston had broke a ring and lodged it in a transformer port before coming to an abrupt halt. Cylinder has about. 1/4” deep gouge, the powervalve flap was damaged and of course the head had taken a beating from loose debris bouncing around inside the engine for some amount of time. The good news was that the crank and rod bearings were as tight as could be. Other than this and some broken plastics the rest of the bike looked pretty good for a base build, so after the first night this is what we were left with.
While the cylinder was out I got the bottom end of the engine cleaned up and ready to reassemble when the top end came back. There was a lot of caked on oil and dirt, and I did repaint the flywheel and clutch covers, but underneath all the crud was a pretty good looking engine.
I figured all these pretty new and cleaned up parts would need a nice frame to hold them together so the frame got cleaned up, sanded down and a fresh coat of metallic silver. This isn’t the factory beige/gold color, but I like it a lot better personally. Here is the end result.
This is where we sat after one night of reassembly which is often interrupted by my other new addition to the family. Trying to get the moto life started early for him too.
First my exhaust springs were the wrong length so I had to get a shorter one, the petcock leaked gas when turned on, the throttle housing was cracked and lastly the clutch oil has some debris in it and wouldn’t bleed. After waiting on parts to arrive from Rocky Mountain (which by the way always amaze me with their free two day delivery) all of these issues were straightened out and I finally had a chance to finish this project up. My wife had her gallbladder taken out yesterday morning, so I had the remainder of the day off of work to take care of her (but more importantly finish up this bike). Here she is seeing sunlight for the first time since I brought her home in February.
https://youtu.be/PpSAgo7xmtk
The Shop
I have an '04 EXC kinda set up for moto and it is a total blast. Those bikes rule!
everyone that says they had one and sold it regrets doing so horribly.
On the subframe, those inserts that the side panels bolt into; keep those threads lubed and don't over-tighten.
If they start spinning it's a pain fix.
I recall that the airbox on those bikes was pretty leaky, like your airfilter would last all of about 10 minutes. Next time you have the subframe off, seal-up as many gaps as you can.
Also, filter skins help space out the airfilter cleaning intervals.
Congrats on the build and enjoy the ride!
I have a Pro Circuit EXC pipe on mine and it is about due to be replaced.
Pit Row
my 2hunny....
Pics to langhammx@sbcglobal.net ?
Thanks, Shaun
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