My Seized KTM 200 Engine Was Filled with Surprises
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- Опубліковано 10 лют 2025
- Win My KTM 200: kincadepavich....
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KTM 200 build series: • 2006 KTM 200 XC-W Build
Thanks to Millennium Technologies for taking care of this crankshaft and cylinder: millennium-tec...
Thanks to Morgan for his help with this project! Check out the Highland Cycles UA-cam channel: / @highlandcycles
Huge thanks to SXSlideplate for helping me with a skidplate solution for this project! They offer durable skidplates and handguards and are made in the USA!
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As an experienced welder and machinist I offer you this:
I could easily weld that and machine it back to factory tolerances. I might even attempt it for my own case half just for fun. I would NEVER do it for a paying customer.
Those case halves are cast aluminum. The exact alloy is debated a bunch, and to my knowledge KTM has never officially shared the details. 5356 filler rod has worked for me in the past on these case halves, but those weld repairs have been to noncritical areas. It takes tons of pre and post heating with a rosebud to keep it from cracking. It's a PITA and in the end it's very hard to make any guarantees.
If you want to play the "how cheap can I rebuild this motor for" game that's one thing. If you want a reliable engine case that you never have to think about again and can abuse in enduro races for years to come: buy a new one.
I hate typing that, because I like to fix stuff rather than replace, but this one is a real pain.
Dang that's a lot of work! If it were me I'd pony up for new case.
same
repairing it sounds like a cool idea but if there's already 2 major issues, there's probably more
That is a bummer dude. I'm surprised it ran as well as it did with the crankcase leaking like that. A leak would have made it run lean. I wonder if that's why you had to keep enrichening the smart carb? In any case, it should develop better power once it's rebuilt properly. Thanks for the videos!
Weld repairs on cast aluminum that are subjected to high amounts of vibration are very difficult. The likelihood of a repair failing again in the exact same spot is massive. If a repair shop tells you they can fix that thin area of the casting “reliably” I wouldn’t trust them. Not to mention that the welding and subsequent machining are Probly going to be close to the cost of the new part.
Go new. No questions. Remember, hindight is 20/20. Lol.
agreed
Buy once cry once
💯
Don’t be the guy with $12,000 into a $3500 bike but also has to fix it every ride 😂
This is so funny because everyone last video was saying you are running it to lean that's why it blew up. When I said it was something different everyone well not everyone but a lot of people said I didn't know what I was talking about and that I was dumb take that haters
Yeah it didn't sound lean to me really at all, just like a normal small bore bike lol.
Lmaooooo it blew up because of an air leak it was running to lean💀💀💀💀😂😂😂
Gonna be brand new. Cases have seen some stuff. I have tig welded my own stuff back together with success. However i regret not buying new cases. Now they are not available new for my bikes and cost a kings ransom on the used market. Good luck!
If you richen up the mid range the top end will hit harder as it comes on. The crank case will have a little extra lube before the power valve opens and the pipe kicks in, once your on the pipe a perfect mix is ideal. This is why a powerjet is used to lean out the top end to ideal from slightly rich. Its way better on the engine to have a little extra mix coating the parts in a low flow throttle position.
Friends dont let friends dont use V force, the cheap plastic reeds kill engines and they wont warranty your parts , then they blame your engine for damaging their part...
You blame V force? What would you recommend instead?
I was waiting sooo long for this vid
Leave the clutchplates in then you can loosen the nut with the impact. Don´t need the big holder tool for that :)
This isn’t hard on the plates?
@@nickstevens7369 No the oil between all the plates and discs creates enough friction. Works every time
I'm trying this. Good idea
Good way to break a clutch basket
@@microsoft790 Nah its perfectly fine.
Good luck finding cases for these 200s. My friend just rebuilt his and it took forever,like a year or more, to get cases. Rocky mountain eventually got them and the bike is nice. Double check me but the 200, 150, and 125 used the same cases for years 2015 and older, maybe to 09 or something. So if you find one being parted out with good cases that might be an option.
I wonder how it works with production of parts like this after the bike is discontinued. Do they make a certain amount only once and they sit in a warehouse or keep the castings and do a limited runs while you wait a year with orders.
For $600 and it’s actually available new, I wouldn’t give welding a second thought. Maybe if it was cheap enough, but I doubt it would be.
In 13 years of being bike mechanic never liked those clutch holders for undoing might suggest taking pressure plate off leave plates in there hold rag over them and rattle nut off works every time never broken one
i know this is 11 days old..one tip i have used on all my KTMs 125, 250, 250f, 525 ... if you leave the clutch plates in basket and hit the basket nut with impact it will break it loose everytime.
@user-ng6ny I will take it
Good series anybody with money can buy new this is way more entertaining. 🔥✌️
I found your channel because I have the a 1999 ktm 200 and since then it's been my favorite channel.
Heck yeah man glad to have you!
Nice trick with the magnet and the cloth. I’ll be remembering that.
Dude, that sucks! Thanks for the update.
I'm 33seconds deep and paused! Bro this stuffs like a movie! Sad ordeal but man you can put together a video like a legend! Love these quality of videos! So hard to find these days!
Thank you so much for the comment! Really glad you're enjoying. Thanks for watching.
Top job! Now for parts to gitter back to good.
The bore where the output shaft seal is located is fubar so really you need new cases or good used cases.
And thats why you impact that nut clean off like any factory team does. If someone tells you it will damage something on disassembly they are lying. Zero damage unlike that steel clutch holder on a soft aluminum clutch center while applying like 80lb ft of torque which moves the aluminum.
Time to grab some popcorn and read the comments of all the know it all a$$ hats tell you what to do. 😂 keep up the solid work bro. Love the videos.
Goodday my duudes, question for yous. I ride a 2008 kxf450 but I’m not against 2Strokes. I’ve been keen for sometime to rebuild a 2t but thing is I’m a Kawi duude. Which year model is the best for trails and enduro riding? My kxf450 needs a break. I’ve rebuilt the motor twice within 6 months and need some smoke in my life. Awe bless from South Africa 🤙🏼
Totally understand this feeling. Im rebuilding a 1990 DR 250 I got off of marketplace for an absoute steal but the cam journals are toast and a new head is turning out to be really hard to source lol. Had one bite of someone parting one out willing to make a deal and they ghosted me. As much as this sucks its definitely giving the 200 a colorful history!
Haha yep, it happens! Never expected this series to have to take this turn, but here we are!
I have a 2015 KTM 85sx. We didn’t put my air filter on right and it ended up sucking in a bunch of dirt and rust. Crank was bad. We ended up rebuilding the crank and sent the cylinder to US chrome to get it replated. Complete tear down and around $1500 in parts for one tiny mistake.
@Kincade_pavich idk if I can do that. Any questions about the rebuild?
Another great video!!!
I'm surprised that motor ran for as long as it did but it did always sound like it was over revving a bit, when you get the motor back together your going to be surprised at how good a 200 really is, chances of finding good used cases for a 200 is most likely slim to none but at least new ones are still available.
2:06 Always wondered doing mechanics is there a way to identify that a nut is reverse thread without a manual at hand? I remember as a teen I had a Quadracer 250 motor and was working at a car dealership in the yard. At lunch I needed to replace the clutch basket and an experienced car mechanic walked by and stated to one nut "remember thats reverse thread" just by looking at its location and I was about to go hog wild lefty loosy on it. Saved my a$$, but Ive never learned of a rule to know reg or reverse thread?
It’s always opposite of the clutch hub nut. Can also tell by thread travel direction.
i love your bike builds
KTM means Kost To Much !!!
Clean and jb welf the cases the rightway its all about prep work
The right way does not involve JB Weld. No place for JB inside a crankcase in my opinion.
Before I finish watching the video, did you change out the main seals? You could change them from the outside.
Ditch the flywheel weight. The 200 flywheel is already heavier than the sx models. You will probably like the power better
agreed, and run steel clutch plates and enjoy the added zing.
Hey I have Ktm 200 I’m about to go look at, does the bike have enough power to get you around/go up some gnarly hills if needed. I’m a 200 guy so idk if it’s gonna be enough.
Go for a 2013 crankcase, then you can add a Electro starter to your 200!!!
This is my main concern with my 01kx250 as case's are very difficult to find!
New case man!
Love you channel mate
Been following you from the start, love the videos here in the uk 🇬🇧
Appreciate ya!
.. With the roller bearing, remove rollers.. drop in fender washer.. reinstall rollers.. tap washer and bearing drops out ...
👍 Yep, or stack a series of overlapping washers around the inside bearing edge, one big one to sit on top of the bed of washers and then press away
I would die to have the money to buy a dirtbike, especially a ktm or a Huskvarna.. I live in sweden and everyone has got one it feels like, but i cant afford one, but someday maybe just gotta keep working ig, i want to be able to be modifying and rebuilding bikes like u, that would be the dream
The good news top end looks grate the Bad news top end looks grate
So do you have a regular schedule for uploads? UA-cam sucks with the notifications 😂, would love to just throw it in my memory bank if it's a specific day u upload new videos haha
I do not have an upload schedule. Currently working as fast as possible haha.
@@KincadePavich ur good brother just figured I'd ask! Love the content! U do good work and good work takes time!!
Hey KP , what oil ratio are you running?
for the 200 in this video he was doing 50-1
Yep what Ryan said, I was running 50:1. I used to run 40:1 in this and may go back to that ratio, at least to start. I run 32:1 in Japanese bikes.
50:1 is way to lean of a mixture, 32:1 is wut I run and jet my carb
Crank seal plus jb is not a good time. Life goes on. What can you do
Keep on truckin' and get her fixed!
next time try using an impact gun on clutch nut.
Same thing happened to my 144 sx
Is their a weep hole at the bottom end
Do i have a comment other than mine??
fact. that is the best lil dicky song 💯😂
@Kincade_pavich get a life and get a job
Don't pull our chain Kincade, you know as well as everyone leaving a comment knows, you have to go new. To much doubt and risk lol.
love ur channel
Love that song lol Molly by lil dicky if anyone was wondering!
👍👍
PLZZZZZZZ could you build me a bike ?
❤
Dope
Question ?
Why don’t you just buy a stock 250 and tune it
Because he loved his old 200 that he had when he was in high school but he sold it and he just wanted another but they don't make 200's anymore so he bought a used one. But that is why he bought a 200
I have a 200, they are lighter and have really smooth power whereas the 250s have a big hit in the power band and are heavier + the old ktm 250s have a lot of engine vibrations
That's the worst case scenario coming true then. 😞
Is it possible to win a give away in aus
People should really stop using that clutch tool.
Totally weldable, fix them cases man
Go new cases mate
Bravo cmnq.malaeccanica non è la moglie del meccanico
I would try to weld the crank case before paying 600$
5th comment
Grow up
No brainer. Go new. Ever have a DNF cause you knew of a problem and thought you had it rigged good enough? Sucks!
Sell the bike and move on to a newer model ktm. Never was a fan of that generation ktm
You're missing the point of this project
Fart
@834_moto_builds could save those engine cases