2015 KTM 200SX FINISHED

I wanted to throw this motor in a linkage chassis, so I kept my eye out for a 12-15 125/150. I found a 15 150SX that has been trashed. Years of desert racing, lunch beers and an engine rebuilder who didn't know his ass from a hole in the ground left this poor thing in shambles. Must've been a Factory Redbull edition judging by the Redbull can duct taped to the shock.











I found 2 circlips installed in the piston and the other one did more damage than a triggered Karen at a political rally.


Probably end up rebuilding the 150, throw it in the 02 frame and taking the 200 and throwing it in the 15 frame.

So I have three questions for the guys who know this motor.
38mm pwk airstriker from the 15 150sx or 39mm keihin that came with the motor?
2015 or 2003 CDI?
How to tell a 200sx pv governor vs a 125 governor?

So I've been able to get quite a bit of work done on the ol gal over the holiday break. Tore the chassis down and man it was in alot worse condition than I originally thought. Had the make a new exhaust tab and weld it on and there was a pretty big gouge on the bottom of the frame, so I made a plate and tacked it on as well.


So the frame and swing arm are off to the powder coater for a fresh coat. In the mean time I started work on the other chassis parts that have been neglected for the entire 175 hours of ride time. I found some sludge in the hydraulic clutch, not sure how it was still functioning. Same goes for this swing arm bearing, the needles were almost powder and the race was ovaled out beyond belief.




I figured while I was replacing the fluids in everything, might as well throw a layer of cerakote on the brakes, hydro clutch, triple clamps and hubs (the wheels were trashed too). I learned a pretty cool technique and "ghosted" my race number with cerakote on the hubs.

Just put down a base color and take a small amount of left over cerakote and add some white to it and spray it over a stencil. Nothing overly complicated, just thought it would give it a "pop".

Those look pretty sweet I might have to break out the files! And I wish I could find a full carbon silencer that would be pretty damn sweet but will probably just resort to a 250sx silencer off of ebay.

Got the frame and swingarm back for the 2015 and had the powder coater do the rims for the 02 while I was at it.


Got some more cerakote done on the engine cases and the 02 hubs.




  The stock coating on the right side covers and magneto cover were insane to get off. I used some strip ease and it took about 2 weeks for it to eat thru it! Hopefully the cerakote holds up to boot rub but if it doesn't I can always just redo it.




Installed some new swing arm bearings.
If you don't have a swing arm bearing installer I highly recommend it. No more tappa tappa tappa... check...tappa tappa tapparoo


Then packed them to the max with maxima waterproof grease.



Couldn't find any black spokes in stock so had to cerakote a set for the rear wheel, turned out really nice! Plus hopefully they won't corrode as bad now.




I've gotten out of control with cerakote on this build, but I think it looks damn good and I like the fact mud has a tough time sticking to it. Spring time in Utah is normally a sloppy mess so I'll take any help I can to keep the mud off.


Found a pretty cool trick for stripping off anodize. It takes forever to grit blast it off so I started looking for a chemical resolution that could strip it off while I worked on other stuff. Turns out rust stain remover from Walmart will strip it right off in about an hour and then water will neutralize it. So its fairly safe to use around the house. I stripped some AR parts that needed cerakote and the aftermarket foot pegs that came on the 2015. 



Rebuilt the rear shock and coated it black with (again) cerakote. Turned out pretty good and now it doesn't leak.



Got a package from factory connection that I think will add quite alot to this build, but I'll wait till the build is done to show what was in the box.

The 02 is done and already sold. The used bike market is insane right now!


Meanwhile the 2015 200 is on the home stretch. The 200 motor fits right in the frame, but you have to make custom head stays. I just traced the 150 head stays then moved the engine bolt hole up a bit.


Also recoated and rebuilt the ARC levers.

Alright here she is! I think it turned out pretty sweet!