- Location
- The Land Northward (Bountiful), Utah
Looks good so far!
#KeepsTakingMoney - 2002 KTM 200 EXC
- Thread starter Greg
- Start date
rholbrook
Well-Known Member
- Location
- Kaysville, Ut
Get it together and meet us at White Wash in the morning
- Location
- The Land Northward (Bountiful), Utah
Oh man, you're killing me. I can't race and I can't go to White Wash. Have a ton of fun!
- Location
- Grand Junction, CO
I wish! Still waiting on all kinds of parts, lots of work to do still.... it'll probably be at least another month before it's back together.
- Location
- Grand Junction, CO
So the biggest wait with this project has been suspension work, I had a local bike shop here in GJ (Highland Cycles) rebuild the forks and shock, add new springs for a 220# rider and changed from 5W oil to 10W oil in the forks as Stratton mentioned.... they wrapped up the work yesterday! I was excited to have that work completed and had finished up almost everything else I needed to do, so I quickly reassembled the bike (new brake pads, new spark plug, etc), double checked everything and mixed up 2 gallons of fresh ethanol-free gas with some Amsoil SABER oil and poured it into the tank.
I still need to replace the rear-lower shock bushing and set the sag, but after getting it close I kicked over the bike and it fired up on the 3rd kick! Before, the idle was WAY high and the idle screw was broken off, so it was sketchy to try ride. Plus, the lack of any rear shock made it bounce all over. I adjusted the idle a little, let it run a bit in the shop and warm up then took it for a ride! It runs great, but I have a stumble at about 1/3 throttle that clears up on full open throttle. I set the jetting where the JD Jetting instructions recommend for a bike with a spark arrestor, but it's not right. At full throttle, the bike has plenty of poop... it's surprising how much power the little 200 has! And it seems to have plenty of speed with the 6 speed transmission, too. After getting back from the ride, I noticed that the carb was leaking gas pretty good... I replaced the bowl gasket, but noticed that one of the bowl screws felt stripped out. I may have to drill it out and upsize the bolts.
After it cooled down a little, I pulled the needle and raised the c-clip one position (from the 3rd notch to the 2nd from the top) and took it for another ride. I figured it was running too rich, but I'm not sure. It's still stumbling... not quite as bad, so I'll try one more position up on the needle and see what happens. Repacking the silencer made a huge difference, before it was annoying-loud... now it's much more tolerable.
Overall, the bike rides and feels great. I like the size and weight difference compared to a 300, you can tell it's smaller but it doesn't quite have that bottom-end torque. I hear you can adjust the PV to change the hit (the Langston setting) and I may tinker with that if I'm feeling like it.
One of the issues I had was the gas leaking at the petcock. The PO said it was the O-ring, but after investigating you could clearly see that the screws securing the petcock into the tank were loose and stripped out when you tried to tighten them. I really didn't want to spring for a new tank, so I drilled out the remaining chucks of plastic, found a piece of plastic tube that was the right diameter, cut it to length and super glued the hose into place. I let the glue setup, trimmed off the pieces that were left sticking out (with a flap-disc on the grinder!) and then applied anti-sieze to the screws so they didn't pull the super-glued hose out of place. That trick worked great, the screws had plenty of meat to bite to and the petcock was now secure! And once the tank was full of gas, there was no leak!!
I also picked up a bottle of SC1 and that has helped shine the plastics up. I really dig this bike... I still want to sell it once I have the carb sorted out and everything else dialed in, but I could see how fun a KTM 200 EXC would be as a 2nd bike.
I still need to replace the rear-lower shock bushing and set the sag, but after getting it close I kicked over the bike and it fired up on the 3rd kick! Before, the idle was WAY high and the idle screw was broken off, so it was sketchy to try ride. Plus, the lack of any rear shock made it bounce all over. I adjusted the idle a little, let it run a bit in the shop and warm up then took it for a ride! It runs great, but I have a stumble at about 1/3 throttle that clears up on full open throttle. I set the jetting where the JD Jetting instructions recommend for a bike with a spark arrestor, but it's not right. At full throttle, the bike has plenty of poop... it's surprising how much power the little 200 has! And it seems to have plenty of speed with the 6 speed transmission, too. After getting back from the ride, I noticed that the carb was leaking gas pretty good... I replaced the bowl gasket, but noticed that one of the bowl screws felt stripped out. I may have to drill it out and upsize the bolts.
After it cooled down a little, I pulled the needle and raised the c-clip one position (from the 3rd notch to the 2nd from the top) and took it for another ride. I figured it was running too rich, but I'm not sure. It's still stumbling... not quite as bad, so I'll try one more position up on the needle and see what happens. Repacking the silencer made a huge difference, before it was annoying-loud... now it's much more tolerable. Overall, the bike rides and feels great. I like the size and weight difference compared to a 300, you can tell it's smaller but it doesn't quite have that bottom-end torque. I hear you can adjust the PV to change the hit (the Langston setting) and I may tinker with that if I'm feeling like it.
One of the issues I had was the gas leaking at the petcock. The PO said it was the O-ring, but after investigating you could clearly see that the screws securing the petcock into the tank were loose and stripped out when you tried to tighten them. I really didn't want to spring for a new tank, so I drilled out the remaining chucks of plastic, found a piece of plastic tube that was the right diameter, cut it to length and super glued the hose into place. I let the glue setup, trimmed off the pieces that were left sticking out (with a flap-disc on the grinder!) and then applied anti-sieze to the screws so they didn't pull the super-glued hose out of place. That trick worked great, the screws had plenty of meat to bite to and the petcock was now secure! And once the tank was full of gas, there was no leak!!
I also picked up a bottle of SC1 and that has helped shine the plastics up. I really dig this bike... I still want to sell it once I have the carb sorted out and everything else dialed in, but I could see how fun a KTM 200 EXC would be as a 2nd bike.
glockman
I hate Jeep trucks
- Location
- Pleasant Grove
Looks really good Greg. I picked up a KDX 220 that I am restoring. It's been surprisingly enjoyable and rewarding taking a turd and polishing it a bit.
rholbrook
Well-Known Member
- Location
- Kaysville, Ut
I'll meet you on Mary's Trail when you are ready
- Location
- Grand Junction, CO
Thanks Chad! I think the reward is 3 fold; First, fixing up a neat bike that was otherwise destined to rot away. Second, gives me something to do and tinker with. Third, hopefully I can make a little money on it!
Those KDX's are neat, sounds like a good one to restore!Don't hold your breath... my shoulder is still messed up and my insurance settlement from the accident that caused the injury has turned into a law suit. I'll be staying off bikes for awhile.
- Location
- Grand Junction, CO
Finally worked on this thing again recently, I lowered the clip on the needle 2 positions, put a new seat cover on and added the new side panels finally. Took the bike out for a test ride and.... this little thing RIPS!! No bog anymore, the bike just needed more fuel. It pulls pretty hard on the pipe, but still has surprisingly decent low end for a 'lil 200. The EXC 6 speed transmission is awesome, I was hauling ass around my neighborhood and pretty sure I saw North of 60 MPH and it still had PLENTY to go. I'm certain I pissed off a lot of neighbors.
The frickin carb is still leaking! Not sure where, it has a new bowl gasket and I upgraded the bowl screws from Phillips to Allen head so I could tighten them a little more. I may take it to a good local shop and just pay them to fix the leak... I've tried 4x to stop it with no luck.
I also ordered 2 Artrax SX1 tires for the bike.... the rear tire is decent with plenty of life left, but the front is shot. I'll give the new owner the bike with 2 new tires, they can put them on as needed.
Here's some pics of the changes. -
Once the carb leak is fixed and the tires are in hand, it'll go up for sale!
The frickin carb is still leaking! Not sure where, it has a new bowl gasket and I upgraded the bowl screws from Phillips to Allen head so I could tighten them a little more. I may take it to a good local shop and just pay them to fix the leak... I've tried 4x to stop it with no luck.
I also ordered 2 Artrax SX1 tires for the bike.... the rear tire is decent with plenty of life left, but the front is shot. I'll give the new owner the bike with 2 new tires, they can put them on as needed.
Here's some pics of the changes. -
Once the carb leak is fixed and the tires are in hand, it'll go up for sale!
- Location
- The Land Northward (Bountiful), Utah
What's your final jetting? I've got a new 2002 125 sx I'd like to rejet.
- Location
- Grand Junction, CO
185 main jet, Red needle with the clip at the bottom. I used the JD Jetting kit and went by their recommendations for a bike with a spark arrestor and it wasn't spot on.