At the 2:36 mark I see a problem. On the countershaft the "Stepped washer" is a shim. It goes between the countershaft bearing and the 25mm seal. It shims the collar with o-ring against the countershaft sprocket, creating a seal. It does NOT go inside the case shown. 125-144-150-200 KTM's have this shim. Other 2 stroke models do not. If your counter shaft is not sealing, it is due to this incorrect setup.
I'm going to try this on my 200xc soon. Never cracked a case open before. Thanks for the information. Between this and the shop manual I feel like it's a doable job. Thank for posting this up.
Now that I know you are about to tear into an engine, here is my advice, buy the black RTV i used in the video and when assembling, put a thin layer on both sides of the case, it holds the gasket in place and makes a nice seal, be very careful applying RTV on the crank side, you want the thinnest layer possible. Also label EVERY screw there will be a lot and some are just a hair longer etc, so make sure you know, and dont use a metal hammer to beat the crank out, you dont want to "mushroom" the end and throw off the balance of the crank.
i know this video was a long time ago, but theres a slim chance i will get a response to this. i have a question about the transmission. i saw that the smaller of the two gears on top sat a little higher than the larger one. all other videos i have seen say that they should sit level but mine sits like yours does in the video. did that cause any problems in the long run or was it fine?
Arizona ginseng honey tea, drank about a 1000 of those. Thanks for the video, helpful i have same year bike. It was just rebuild top and bottom but it's always good to know your bikes guts.
I find it strange that KTM used a gasket between center cases! Most bikes Ihave worked on used no gasket here! Just case sealant and typically? They NEVER leaked! Makes me wonder if KTM lacks technology to make perfect fit? Or is it a materials thing? They use some exotic alloy that is lighter but prone to leak? WTH??
Hi mate the bowl looking washer under the bearing on the shaft is that ment to be there because on everything else on the internet its showing it's not there
It doesn't matter if its in the case first or on the shaft first, they both go together in the end no matter what. Assemble a few engines first before you come over here to troll. This engine ran perfect and drove perfect after i finished it. I take it you must not know what you're doing anyways when you're watching a video on how to assemble an engine.
Um I assemble a lot of motors , Btw I build race engines , And was not being a troll , I was stating a fact, And no I dont I dont record my builds sorry I have to use a flow bench so I need both my hands and no one is allowed the motor room to record
fu K. The bearing wasn't "seized" on the shaft, I could have taken it off and put it on the way you believe it should be done. If you build race engines why are you watching a video on how to assemble an engine, if you do it all day why do you browse youtube to watch videos on it. Why don't you watch videos of this bike running and moving and tell me why my way of assembling it doesn't work. You're nit-picking such a small irrelevant thing that does not affect the motor at all.
On 2 stroke reliability ...it is untrue that "two strokes are more reliable" so long as one is comparing well designed and properly maintained non abused bikes, the four strokes historically last longer. Having said that it IS true that a two stroke has way less moving parts and so can suffer more ABUSE before failing dramatically. Probably the most bang for the buck as far as longevity of non maintained motorcycles? Large displacement 2 stroke ....so long as good fuel/oil is used for the "life" of the machine? And at least the air cleaner is maintained? A big bore two stroke can on average suffer a lot of hours of neglect simply because there are not a lot of folks running around capable of thrashing them at high rpm. But now the smaller bores? They tend to to be thrashed and unable to suffer the hours of neglect anything like the bigger bore bikes can....just saying. But a well used bike that has not been serviced according to the service intervals (which almost NO play Rider actually ever does)? You best factor into the price a complete teardown and lots of new parts to get it back to it's design performance and reliability ....and if too far gone? It literally will not be worth doing ....especially with expensive brand bike...IMHO having "been there done that" too many times to even reliably remember ... I was originally a motorcycle mechanic and had people want to "restore" bikes ....so many times they would wind up in disassembled heaps in boxes because the parts list was overwhelmingly expensive ....way cheaper to go find the same model some guy bought and never rode than to rejuvenate something totally DOA.
At the 2:36 mark I see a problem. On the countershaft the "Stepped washer" is a shim. It goes between the countershaft bearing and the 25mm seal. It shims the collar with o-ring against the countershaft sprocket, creating a seal. It does NOT go inside the case shown. 125-144-150-200 KTM's have this shim. Other 2 stroke models do not. If your counter shaft is not sealing, it is due to this incorrect setup.
I'm going to try this on my 200xc soon. Never cracked a case open before. Thanks for the information. Between this and the shop manual I feel like it's a doable job. Thank for posting this up.
Now that I know you are about to tear into an engine, here is my advice, buy the black RTV i used in the video and when assembling, put a thin layer on both sides of the case, it holds the gasket in place and makes a nice seal, be very careful applying RTV on the crank side, you want the thinnest layer possible. Also label EVERY screw there will be a lot and some are just a hair longer etc, so make sure you know, and dont use a metal hammer to beat the crank out, you dont want to "mushroom" the end and throw off the balance of the crank.
Put the gearbox counter shaft and output shaft beatings in the case first and the case would go on easy back yard mechanics at its best
i know this video was a long time ago, but theres a slim chance i will get a response to this. i have a question about the transmission. i saw that the smaller of the two gears on top sat a little higher than the larger one. all other videos i have seen say that they should sit level but mine sits like yours does in the video. did that cause any problems in the long run or was it fine?
Arizona ginseng honey tea, drank about a 1000 of those. Thanks for the video, helpful i have same year bike. It was just rebuild top and bottom but it's always good to know your bikes guts.
Haha, they are good! And no problem, that's why I took the time to upload it!
I find it strange that KTM used a gasket between center cases! Most bikes Ihave worked on used no gasket here! Just case sealant and typically? They NEVER leaked! Makes me wonder if KTM lacks technology to make perfect fit? Or is it a materials thing? They use some exotic alloy that is lighter but prone to leak? WTH??
Hi mate the bowl looking washer under the bearing on the shaft is that ment to be there because on everything else on the internet its showing it's not there
Cool vid bud, think I am gonna go pick up that clapped out ktm 50 for my daughter now I’m not as worried about doing a bottom end
6:10min - An early kick start test, but the cylinder was missing the spark plug.
That bearing is seized on the primary shaft , It should be in the case first
It doesn't really matter.
ok a bearing that holds the primary shaft straight does not matter
It doesn't matter if its in the case first or on the shaft first, they both go together in the end no matter what. Assemble a few engines first before you come over here to troll. This engine ran perfect and drove perfect after i finished it. I take it you must not know what you're doing anyways when you're watching a video on how to assemble an engine.
Um I assemble a lot of motors , Btw I build race engines , And was not being a troll , I was stating a fact, And no I dont I dont record my builds sorry I have to use a flow bench so I need both my hands and no one is allowed the motor room to record
fu K. The bearing wasn't "seized" on the shaft, I could have taken it off and put it on the way you believe it should be done. If you build race engines why are you watching a video on how to assemble an engine, if you do it all day why do you browse youtube to watch videos on it. Why don't you watch videos of this bike running and moving and tell me why my way of assembling it doesn't work. You're nit-picking such a small irrelevant thing that does not affect the motor at all.
How tf did you disconnect the electrical wires??
is there any washer behind the bearing on 2nd main shift?
can I use 03 ktm125sx left side casing on my o4 ktm125sx. are they the same?
Is this the same engine as a 2002 sx?
Great vid, is 'Gear oil' regular transmission oil??
Why do you use gear saver oil on some bearings, and 2 stroke oil on others? How do I know which to use on which bearings?
+Jon Jelen the transmission are use gear saver, the crank area use 2 smoke oil
Crank bearings are lubed by premix. Thats why you dont listen to your idiots friends when they tell you to run 100:1.
nice you help me a lot
Hi mate awesome vid 👍🏻, I have a 2012 exc 125 that I would like to rebuild myself, would there be any difference between your engine and mine ?
the engines from the 2004 125 sx are the same as the engines in the 2011-2015 125 sx😀
where did you get the diagram on you phone???@Cody Sidlik
Rockymountainatvmc.com Just click OEM parts, and type In the Year Make and Model and they will have diagrams.
dobra robota
On 2 stroke reliability ...it is untrue that "two strokes are more reliable" so long as one is comparing well designed and properly maintained non abused bikes, the four strokes historically last longer. Having said that it IS true that a two stroke has way less moving parts and so can suffer more ABUSE before failing dramatically. Probably the most bang for the buck as far as longevity of non maintained motorcycles? Large displacement 2 stroke ....so long as good fuel/oil is used for the "life" of the machine? And at least the air cleaner is maintained? A big bore two stroke can on average suffer a lot of hours of neglect simply because there are not a lot of folks running around capable of thrashing them at high rpm. But now the smaller bores? They tend to to be thrashed and unable to suffer the hours of neglect anything like the bigger bore bikes can....just saying. But a well used bike that has not been serviced according to the service intervals (which almost NO play Rider actually ever does)? You best factor into the price a complete teardown and lots of new parts to get it back to it's design performance and reliability ....and if too far gone? It literally will not be worth doing ....especially with expensive brand bike...IMHO having "been there done that" too many times to even reliably remember ... I was originally a motorcycle mechanic and had people want to "restore" bikes ....so many times they would wind up in disassembled heaps in boxes because the parts list was overwhelmingly expensive ....way cheaper to go find the same model some guy bought and never rode than to rejuvenate something totally DOA.
is sx and exc the same motor ?
Yes.
thanks
300th like
Camera movement made me sick
Do not watch this video if you're a beginner, he forgot o rings and many important components