I Spoke With My......Greasy Hands

hellion
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Westfield, MA US
Edited Date/Time 6/12/2019 6:24am
Over the years I've ridden every size and configuration possible, from all the brands. I always came back to KTM though mainly because they just seem so much more well put together. And, even more specifically, I keep coming back to my old faithful 200SX. KTM only made the 200SX for two years, 03' and 04', and even now almost ten years later they still have a very loyal following. I tried to make other 200 models run the same, they just never really did. I've had four of the 200SX's over the years, and bought an almost new model to make a recent hybrid 10' 150 into 200SX.

A month ago I felt the desire to update from the 12' 250SX I was riding, so a 13' 150SX found it's way home. I bought it with the plan of immediately putting the 200SX drivetrain in, but was surprised to really like the 150 motor. Even at 200lbs it hauled me around really well. But, at the end of the day I wanted the torque the 200 motor offered, plus I missed the ability to pull taller gearing which made for a wider gear spread. That, and finding a 200SX exhaust (like new Doma pipe and silencer) that I've been looking for for years got me thinking the project needed to happen now.

So, here it is. The bike I wish KTM would make again. But if they don't, I will do it myself I guess. And, no, I didn't paint the frame orange. It was a close call, it may still happen over the winter, but I find the metalic grey growing on me. And I like stock looking bikes too.










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Katoom72
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10/22/2012 11:00am Edited Date/Time 10/22/2012 11:01am
Great job! The 200 is a terrific enigne, to bad they are hard to come by used over here.
newmann
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10/22/2012 11:02am
Looking for the like button because I do like that approach.The 200 2 stroke should be the legal equvilent for the 250F class.
10/22/2012 11:02am
Pretty sweet bike. I'm not a KTM fan but the return of the 200SX would be enough to get me to make the switch.

Did you mod the 150 with 200XC parts or did you install an older 200SX engine?
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hellion
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10/22/2012 11:07am
Sheriff245 wrote:
Pretty sweet bike. I'm not a KTM fan but the return of the 200SX would be enough to get me to make the switch. Did you...
Pretty sweet bike. I'm not a KTM fan but the return of the 200SX would be enough to get me to make the switch.

Did you mod the 150 with 200XC parts or did you install an older 200SX engine?
Full 200SX engine, carb,ignition, exhaust, and gearing.

The Shop

FreshTopEnd
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10/22/2012 11:18am Edited Date/Time 10/22/2012 11:19am
Nice! I'm rehabbing an 08 200XC (wanted the close ratio tranny); second 200 (sorry I sold the first bike). Had some head work done and will be putting a PC works 200SX chamber on it, cdi and maybe a carb switch down the road. I do like the conversions with the new frame/linkage. Did you see AC's 2012 200XC thread on his at KTMTalk?

http://ktmtalk.com/index.php?showtopic=453703&hl=
hellion
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10/22/2012 11:24am
Nice! I'm rehabbing an 08 200XC (wanted the close ratio tranny); second 200 (sorry I sold the first bike). Had some head work done and will...
Nice! I'm rehabbing an 08 200XC (wanted the close ratio tranny); second 200 (sorry I sold the first bike). Had some head work done and will be putting a PC works 200SX chamber on it, cdi and maybe a carb switch down the road. I do like the conversions with the new frame/linkage. Did you see AC's 2012 200XC thread on his at KTMTalk?

http://ktmtalk.com/index.php?showtopic=453703&hl=
FTE, don't forget the SX powervalve timer.
burn1986
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bossier city, LA US
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10/22/2012 12:28pm
Wow, it looks like it came that way from the factory. Was it hard making everything line up?
yak651
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10/22/2012 12:54pm
nice, what are you doing with the 150 engine?
hellion
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10/22/2012 1:41pm
The only fab was the head stay, which was really easy. The ignition box needed some trimming to fit in the stock location too. But everything else lined up nicely, mainly because the 150 and 200 share engine cases.
burn1986
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10/22/2012 1:59pm
yak651 wrote:
nice, what are you doing with the 150 engine?
Yeah, really, that could be a high priced commodity.
hellion
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10/22/2012 2:14pm
yak651 wrote:
nice, what are you doing with the 150 engine?
burn1986 wrote:
Yeah, really, that could be a high priced commodity.
Sorry, the most valuable thing in the project to me is the 200SX engine and associated stuff. That means I'll be keeping the 150 to put back in the bike when it's time to sell and the 200 stuff stays for any future projects. I've sold all my 200 stuff twice and regretted it both times. I don't think I'm dumb enough to do it again, at least I hope not. New bike fever is strong though and makes you do regrettable things lol sometimes. So though I may be enticed to try a different size or stroke, I'll always have it to fall back on.
1
level
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10/22/2012 3:26pm
Your right-the gray does look better.
Falcon
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10/22/2012 3:31pm
Your hubs are killer.
Derpin' DJ
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10/22/2012 4:03pm
newmann wrote:
Looking for the like button because I do like that approach.The 200 2 stroke should be the legal equvilent for the 250F class.
I'll agree with that Smile

My bro just bought a 2012 200 EXC. Looking forward to having a crack at it
10/22/2012 4:58pm
Damn, there is a whole bunch of nutty KTM loving 2 strokers on this board! Wink

If I was a whole lot skinnier and younger your 200 project would be perfect for me, but the 300 will have to do for now.

Great projects, thanks for posting them up. Smile
T-Fish
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10/22/2012 5:29pm
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was bidding on it as well. I'm doing the same thing you are.
10/22/2012 5:47pm
T-Fish wrote:
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was...
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was bidding on it as well. I'm doing the same thing you are.
Smile
newmann
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10/22/2012 5:48pm
T-Fish wrote:
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was...
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was bidding on it as well. I'm doing the same thing you are.
You let him snipe ya'?
T-Fish
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10/22/2012 6:09pm Edited Date/Time 10/22/2012 6:09pm
T-Fish wrote:
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was...
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was bidding on it as well. I'm doing the same thing you are.
newmann wrote:
You let him snipe ya'?
Yeah, there were a few bidders that showed up at the end. I was working and in a bad area for cell reception, so I knew I had no chance of sniping the auction. This might not even be the same exhaust, but I have a feeling it might be.
PC
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10/22/2012 7:05pm
Right on!
If they dont make it, build it.

I've got a Husky cr125 that I love riding in the woods, but at 200 lbs it can be a struggle in the back country to get up some of the gnarly stuff. I bought a OEM 144 kit and it helps, but is no game changer. However, I just got a custom 165cc top end and (am about to receive) a custom made KTM 200 Fatty pipe to work with it. Small-bore chassis, mid-bore power.

If the OEM's dont want to provide then some crazy red blooded American will! What a country.
1
hellion
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10/23/2012 5:49am
T-Fish wrote:
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was...
Did you get that Doma exhaust off of eBay, for a winning bid of $248.51 that ended on September 15th? If so, damn you, I was bidding on it as well. I'm doing the same thing you are.
newmann wrote:
You let him snipe ya'?
T-Fish wrote:
Yeah, there were a few bidders that showed up at the end. I was working and in a bad area for cell reception, so I knew...
Yeah, there were a few bidders that showed up at the end. I was working and in a bad area for cell reception, so I knew I had no chance of sniping the auction. This might not even be the same exhaust, but I have a feeling it might be.
Yes, that's the one. I've been looking for that exhaust for years and years and couldn't believe it when it finally showed up on fleabay. It's as good as new, so nice that I don't really want to ride with it until I get a carbon guard for it. Also, I was willing to pay double what I got it for, pretty sure we won't see one come up again.
resetjet
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10/23/2012 5:54am
Ok, I have a 03 and an 04 200 EXC. What exactly is the difference between motors on an SX???? If the motors are that good, can I mod my exc motor????
hellion
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10/23/2012 6:51am
The cylinder and crank and cases are all basically the same. Gear ratios, piston, ignition, stator, carb, pipe, and power valve timer are different. I've had XC's that I tried to make run the same and though I got close they were never what I was really looking for. It was just a magic combination, at least for me and a few others out there.
nytsmaC
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Frig Off CA
10/23/2012 7:55am
PC wrote:
Right on! If they dont make it, build it. I've got a Husky cr125 that I love riding in the woods, but at 200 lbs it...
Right on!
If they dont make it, build it.

I've got a Husky cr125 that I love riding in the woods, but at 200 lbs it can be a struggle in the back country to get up some of the gnarly stuff. I bought a OEM 144 kit and it helps, but is no game changer. However, I just got a custom 165cc top end and (am about to receive) a custom made KTM 200 Fatty pipe to work with it. Small-bore chassis, mid-bore power.

If the OEM's dont want to provide then some crazy red blooded American will! What a country.
Doing the same thing here! Mine is on the way with a custom HGS pipe and race gas only setup, can't wait to run it in and get it on the dyno. I'll post dyno charts when I'm done. The 144 setup I have is awesome for moto, didn't need to go the 165 route but I had that stock 125 jug just sitting there collecting dust, so I figured what the hell.
newmann
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10/23/2012 8:33am
Sheriff245 wrote:
Mind telling us where you found that 200SX engine?
Something tells me that there is an engineless carcass in the back yard.Smile
PC
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10/23/2012 8:36am
nytsmaC wrote:
Doing the same thing here! Mine is on the way with a custom HGS pipe and race gas only setup, can't wait to run it in...
Doing the same thing here! Mine is on the way with a custom HGS pipe and race gas only setup, can't wait to run it in and get it on the dyno. I'll post dyno charts when I'm done. The 144 setup I have is awesome for moto, didn't need to go the 165 route but I had that stock 125 jug just sitting there collecting dust, so I figured what the hell.
Cool! I'm enjoying the hell out of the 144 too, but I got a 5hr old 165 setup for half price, so I jumped on it. Up until yesterday I had a 124, 144 and 165 top ends, but I shipped the 124 to Walt yesterday so someone else can have a 165.

Now that I've got the 165 kit the wr300 is going up for sale. After spending time on the small bore I can barely stand to ride it anymore. Overweight, overpowered ill handling pig! Same goes for my YZ. Damn small bore has ruined all other bikes for me.

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