Posts
303
Joined
12/25/2013
Location
Lascassas, TN
US
Edited Date/Time
10/26/2019 6:34pm
How's it goin everybody, my name's Josh and I just joined the site even though I get on here all the time.. usually just to check out the "kick ass two stroke" thread. . I grew up riding a little bit of everything.. and now that I am older I mostly just play ride on the tracks.. well I have been working on building my idea of the perfect motorcycle for me and am going to do my best to document every bit of it.. frame is a 2008 rmz 250 and the motor is a ktm 200 sx (by far my favorite engine ever built) feel free to chime in whenever, and I have a little hot rod shop facebook page that I will be posting build pics on too.. its called Halls Hot Rods.. 
Then pulled out the ktm motor.. this motor only has about 2 hours on it after a full rebuild.. had my frame powdercoated too.. oh well.. still not sure if I want to save this chassis or just sell it.. guess it depends on how tbe finished product turns out
First off had to figure where I was at with the width of the motor in correlation to the swingarm.. ktm motor was about a half inch wider than the rmz at the swingarm pivot
The Shop
great little project you have going on there so i subscribed
I made the cuts with a fine tooth sawzall right at the factory welds to remove the front down tubes.. but in order to get the right angle for the engine and line up the swingarm pivot I had to remove about 3 inches from the main downtube in order to move the "Y" up enough to clear the head
There she sits with the pipe and tank.. new downtubes coming up next
Here's the right side.. I really would love to talk to some of the guys that fool with these 200's to get their info on what pipes to run.. the fmf pipe that I have ran great but I have seen some 200s running a 150 pipe .. didn't know how that turned out but I would sure love to know.. I can't find a bare pipe for a 200 sx anywhere
For the head stay I did it like a Honda CR250 frame. I've seen some where the stock RMZ head stay mounts are used, the ones on the frame spars. From what I've read the stress on the head stay is front-to-back. If you used the stock RMZ head stay mounts you are just getting side-to-side rigidity. Check out a CR frame.
I've been riding mine for over a year and its still in one piece.
I got a stick of 6061 from a local welding shop and used thick inserts I had for the same reason u were describing with weld penetration.. I z-notched the upper tube ends to get a little more weld surface..same thing we do at the shop when shortening or extending hot rod frames.. just on a smaller scale.. and I cut the lower tubes parallel with the ground.. mostly because I thought it looks cleaner. And the upper "y" actually slides into the downtube about an inch.. notice the super works frame jigs I am using for mock up.. lol
Pit Row
And there she sits.. motor and swingarm all set.. now time to fab up some motor mounts
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