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2015 Ktm 200

2015 Ktm 200

Forum Main Bike Builds 2015 KTM 200SX FINISHED

2015 KTM 200SX FINISHED

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

12/18/2020 7:11 PM

So normally I keep my eye out for blown up bikes, especially KTM's. I found this 02 250SX in the classifieds saying basically it was torn apart and they lost interest. Sounded good for $800 as buddy bike, but when I arrived I could tell right away it was not a 250. The VIN matched the title and the title definitely says 250, but this was definitely a 200. The adjustable power valve was a dead give away and the seller seemed equally confused about the whole deal, but he wasn't completely clueless as he had already bought a crank and gaskets for the 200 motor.
Knowing how loved the 200 motor is, I quickly bought it and started sorting the motor out. Photo
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I'm gonna throw a coat of cerakote on the cases and send the cylinder out for new nikaseal. In the mean time I have to figure out what I have here, the transmission is definitely a 200sx tranny, the carb is a 39mm, and the CDI is a 2k3. I have a few questions for you guys who know this motor inside and out, how do you ID a 200 sx power valve governor from a 125 governor? Does a newer CDI gain anything on this motor? I have both, just curious which one is better to run for track riding? Photo

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

12/18/2020 7:52 PM
Edited Date/Time: 12/18/2020 8:42 PM

hanzhongluboy

Posts: 85

Joined: 1/29/2020

Location: Texas panhandle, TX USA

12/18/2020 9:28 PM

gonna be sweet.

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

12/19/2020 9:06 AM

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?

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

Phillip_Lamb

Posts: 1584

Joined: 12/14/2010

Location: ORANGEVALE, CA USA

1/3/2021 8:32 PM

this project is sweet

"If you feel in control, you're not going fast enough" ~Mario Andretti

FarleyMX25

Posts: 118

Joined: 10/2/2017

Location: Harrison, TN USA

1/3/2021 9:51 PM

What was the process for ghosting your numbers?

Instagram @factoryfarley25

XC706

Posts: 177

Joined: 1/7/2016

Location: CAN

1/3/2021 10:00 PM

This build is gonna be great. I had a 2003 & 2004 SX 200, ran the 39 Keihin with a Doma black chrome pipe and a Acrebis C35 carbon muffler and it ripped! Unfortunately both of those are probably impossible to find.
After I Ceracoated my calipers I took a fine jewelers file to the name and logo. Photo
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Lowlander

Posts: 192

Joined: 3/31/2012

Location: Perth, AUS

1/4/2021 1:48 AM

Looking to do the same build. Need to find a roller. The 200 is just a great engine.

CR250 07
KTM 200 2016 EXC (XCW)
KTM 150 2018 EXC (XCW)
Husqvarna TE150 2019
Husqvarna TC125 2019
KX85 Supermini 2014
YCF 125 Bigy 2018

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

1/4/2021 9:40 AM

FarleyMX25 wrote:

What was the process for ghosting your numbers?

FarleyMX25 wrote:

What was the process for ghosting your numbers?

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".

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

1/4/2021 9:42 AM

XC706 wrote:

This build is gonna be great. I had a 2003 & 2004 SX 200, ran the 39 Keihin with a Doma black chrome pipe and a Acrebis ...more

XC706 wrote:

This build is gonna be great. I had a 2003 & 2004 SX 200, ran the 39 Keihin with a Doma black chrome pipe and a Acrebis C35 carbon muffler and it ripped! Unfortunately both of those are probably impossible to find.
After I Ceracoated my calipers I took a fine jewelers file to the name and logo. Photo
Photo

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.

XC706

Posts: 177

Joined: 1/7/2016

Location: CAN

1/4/2021 10:55 AM

There is way to get a full carbon muffler for your bike. Purchase a Bud Racing carbon muffler for a SX 250, they are cheap to buy. Cut off the stinger, weld the stinger from the stock muffler to the Bud can.The Bud has the clamp style mount on the can so you can move to align with the muffler mount hole.
I just did the exact same thing on a 2020 XC 250 Photo with a 2nd C35 I had purchased new and have had it stached in a drawer for 20 years.
Worked perfect and is less than half the weight of the stock muffler, gave the bike a nice boost in bottom and Mid power.
Photo

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

3/20/2021 12:59 PM

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. Photo
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Got some more cerakote done on the engine cases and the 02 hubs.
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  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.
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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
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Then packed them to the max with maxima waterproof grease.
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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.
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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.
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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.
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Rebuilt the rear shock and coated it black with (again) cerakote. Turned out pretty good and now it doesn't leak.
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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.

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Rickyisms

Posts: 2470

Joined: 10/5/2017

Location: Bradenton, FL USA

3/20/2021 9:26 PM

Black cone valves?πŸ€”

Build(s) are going to be sweet!

Unleaded tastes a little tangy. Supreme is kinda sour, and diesel tastes pretty good.

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

5/16/2021 7:48 AM

The 02 is done and already sold. The used bike market is insane right now!
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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.
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Also recoated and rebuilt the ARC levers.
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soggy

Posts: 2069

Joined: 12/3/2018

Location: UT, USA

5/16/2021 4:39 PM

Levers look rad

YZed250

Posts: 702

Joined: 11/9/2014

Location: Costa Mesa, CA USA

5/19/2021 2:47 PM

Spokes look rad, too!

KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

5/25/2021 8:06 PM
Edited Date/Time: 5/27/2021 5:38 AM

Ktm life

Posts: 126

Joined: 12/17/2012

Location: Tremonton, UT USA

5/27/2021 1:40 AM

Awesome build!! Looks cool something different to the usual!!

TunaBro

Posts: 405

Joined: 1/3/2020

Location: Lake Stevens, WA USA

6/10/2021 10:02 AM

Man, I dig all the coatings. Came out rad. Well done!

2015 YZ250F - 2003 CR125R

Phillip_Lamb

Posts: 1584

Joined: 12/14/2010

Location: ORANGEVALE, CA USA

6/10/2021 10:50 PM

noice

"If you feel in control, you're not going fast enough" ~Mario Andretti

Forum Main Bike Builds 2015 KTM 200SX FINISHED

2015 Ktm 200

Source: https://www.vitalmx.com/forums/Bike-Builds,46/2015-KTM-200SX-Experts-needed,1385220