I Added Electric Start to My 18 Year Old KTM 200 2 Stroke

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KTM 200 build series: • 2006 KTM 200 XC-W Build
Thanks to Randy Rowe for supporting this electric start installation! If you need excavation work in the Missoula, MT area, get in touch with him!
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Fast Metric fastener kits:
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The Magura 167 master cylinder made a world of difference in the way this clutch pulls!
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Chapters:
0:00 Teardown
1:12 Petcock Relocation
4:58 Wiring Setup
6:30 New Stator Required
7:41 Hard Enduro
9:46 Overheating
15:28 Electric Start Installation
17:01 Pipe and Chain Guide
17:43 Testing Electric Start

[@stephenbrooker4402]

Y'know it a good day when Kincade posts

[@dirtbiker2013]

for real

[@dirtbikemike2956]

and deuces and rather b welding all in the same day

[@hunterduppong1410]

🎉

[@JesseAnsley]

I can agree!

[@JaxsonM22]

Your reaction to the e start working was pricless😂😂

[@Andreas.619]

If more people rode dirtbikes, everyone would be way happier.

[@DjBoBo142]

great project with very good ideas. I'm currently re-bathing my old KX65 with my children. greetings from Germany

[@averykienbaum2904]

BRO YET AGAIN! SLAYING IT WITH ANOTHER GREAT VIDEO! SO COOL THE EXCAVATION company helped you out, and ur follower for the pipe etc!! Wild

[@kenwolfe5697]

That riding looked gnarly as hell. Nice work on the e start

[@onthethrottle7104]

Great friends, super awesome bikes, gorgeous Montana landscape, hard enduro...make sure to always embrace and remember times like these because it doesn't get any better!

[@brettlaage9687]

Awesome. I would have had someone weld a 90 degree barb to a custom flange to put in place of the petcock, then put an inline valve and filter. I understand that would take some extra time to do. Anyways, good work and riding.

[@ilmangiamandragole7857]

Love your videos, super quality content. I like that u advertise small brand and useful website. And there this cool "garage vibe" I love it

[@NickSchoess]

Wow, incredible work on all of the workarounds needed to get this going! I'm hyped to see the next video where you're able to test the fan and charging system properly!

[@anythingoutdoors0]

I got so excited when the electric start just perfectly worked and the bike started instantly. Can't wait to get a proper hard enduro bike 😬

[@Danman1972]

Seal those ends on the button connector. They will fill up with water and rot eventually. Some dielectric grease and tape will keep the water out. My 06 KTM450 had that set up and the second time it happened that is what I did. It worked.

[@msaul85]

I am not a usual video commenter but I had to commend you on that gas tank. Great job! Bravo! That petcock relocation solution was simple yet complex and very well executed. Good job dude!

[@KincadePavich]

Haha thanks a ton! I was definitely nervous, especially with the new mounting location. I'll admit I'm somewhat surprised it didn't leak after the first iteration, but I am stoked!

[@coopkink]

dude i just got a new 2023 250xc and I'm soooooooooooooo pumped for my electric start. gone are the days of kicking a bike on a steep grade

[@major_rabbits]

that's crazy no hold just push it activated instantly great vids keep it coming

[@AjackLee4]

This series has been one of my favorites!

[@TwoThreadsAhead]

You've done a spectacular job bringing this bike up to date, she looks great!

[@juustopala166]

I also started a project bike from the reassurance of watching your videos just this week, thanks for the inspiration!

[@KincadePavich]

So awesome man! Good luck with it!

[@thatdudeneep]

Good job brother!

[@catmoo84]

loving these videos! I think I love the 200 build because I have a 2006 EXC 200 at home in my garage still and this gives me inspiration to pull it out of the shed and fix it up and ride it again. so cool! keep up these awesome videos, look forward to seeing you race the hard enduro on this beast.

[@gunnarpettus1010]

Letssss goooo! That electric start got me fired up 💯🤘

[@robh3267]

Do not ride that bike until you get the overheating issue dealt with, you should have never continued riding on that trail with an overheating bike, 270 is seizing territory, it still sounds like your too high in the rev range, you might want to gear it down a little, nice job on the e start, that will make a big difference in tough situations.

[@Dirtbikeguy-lz7hh]

Mine didn’t seize but ruined the integrity of the aluminum to the point that the head bolts stripped at 10ft pounds and the torque spec is 20

[@bmusic0912]

Honestly he’s prolly put more money into this than a new Ktm 250 but here’s the thing….. the 200 2 stroke engine is such a good engine that I would take that over a new 250 or 300

[@diyjeff1838]

This waa one of my recommendations. I wish they made a kit for my 2005 crf 450.

[@grantlingley1385]

Love these videos. Subscribed for sure and thanks for all of the work editing. I am on my 300 XCW now but started with a 2001 200 XCW and miss that bike every day! LOL My 300 is an ‘09 so a little older as well but it works really well!

[@dean754]

Started on the button! Woohoo! I literally laughed out loud! 🏁🏁🏁

[@OffroadTakeover8]

Sick brother 🔥

[@theibault]

That ride was awesome.

[@christianfriden755]

Great video. Got the 200 -14 myself and freakin love it. Rarely uses the electric start though, because the bushing wear out pretty fast, causing the gear mesh to be offset. It always start on the first kick when its warm so it's really not that big of a deal. But its sure is nice to have

[@griffithracingteam2412]

Tokyo offroad offers brass ones that significantly outlast the oems I highly recommend them. just make sure you get the right kit. there are different ones. you can also get them on slavens racing

[@diyjeff1838]

Such a game changer.

[@KadeMcBain]

the e start is great

[@sfmountainbiking612]

Hell yea brother 🤙

[@nathanmcbrayer6755]

I love watching your videos

[@XanderSumner]

I desperately need a e start kit for my bike but I don’t think the make them for 40 year old bikes lmao

[@sergiomonohoma.]

Good job!!!

[@aitordelpozo]

mate you´r the beast

[@poof1907]

1:02 im buying that 1 million percent. fastest amazon purchase of my life

[@joelatkinson2080]

If you want to be great at hard enduro then follow Billy Bolt's example and get really good at trials riding. It's a good excuse to get a trials bike. Another great video!!!

[@Regan_Tatham]

Man I wish my e start on my 2013 200 worked that good, even after replacing the bushes it still only works when the bike is warm.

[@nicholasogborn9212]

can you make a parts list? Id like to do this to my 2008 300 xc. Thanks!!!

[@Dirtbikeguy-lz7hh]

You should do a Kx500 or Cr 500 build next also be careful with the over heating caused my husky head bolts to strip before I could torque them on my next rebuild

[@ShawnBlais]

Nice work! The relay normally sits in the top-right corner of the airbox fyi. Fan should be set to 190, and that should keep it under 210 no matter what. 150 will result in your fan being on nearly 100% of the time, and will kill your battery pretty quick if you have the OEM stator.

[@ronlawson5819]

That was a wild video,that trail was nasty will the new setup charge the battery and run the fan

[@Frostbyte911]

Great video as always. What coolant do you use?

[@Altie8]

yay

[@revelized]

howd that pisto look after getting it up to 270* ?

[@camarofix]

try running engine ice coolant

[@jamesolivier3192]

Heck yeah !!! so cool. never realized that you could add e-start to the older bikes. would this be the same for an 06 300?

[@nevadahardenduro]

Yes

[@smward1126]

How did you fix the fan ?

[@JamesBurr-vk7kh]

Heck yeah 👍💯

[@Sunspot-19]

Shoulda been rolling a trials bike for that terrain.

[@antoniohidalgo1473]

Hello, magnificent project, could you put the references of the cables used that appear in the video, I am doing a similar project. thank you

[@shaunbean5553]

Put the relay in the air box out the way of all the elements specially water!.. get a custom mount made

[@KincadePavich]

Hehe actually made that change this week! Custom mount = zip tie 😂

[@Unqualified2ride]

Let’s gooo

[@timberporter]

Did you have to replace engine cses (both sides) for the e start conversion? Or was it only the black flywhweel/stator cover?

[@KincadePavich]

Requires new engine cases

[@cursetheserpent]

Everytime I see this bike I am reminded how bad I want this bike. You rule bro!

[@motionfactoryracing5914]

"Cheat Mode" engaged!

[@timeistheway4893]

W🎉

[@ianallen6618]

250 is engine damage level temps. Hopefully everything survives and is okay!

[@RockySuset7155]

How much for you to put an electric start on my Yamaha it is a 2006

[@MrJeffharper47]

Goodness that petcock installation was something…

[@oznik46]

Hat off…these videos are getting better and better! So freaking awesome! A note regarding those starter bushings that tend to have a limited lifetime, known issue on KTM’s that eventually may result the need to replace the cases if not looked over as the bendix grinds through the aluminum. XRC has an upgraded brass bushings kit (Slavens sell these) though the only kit that is for your model year seems to fit 250/300 but I’d go and do some measuring and research, I can’t see a reason why these shouldn’t fit your bike.

[@griffithracingteam2412]

they're the same. just get same year 250/300 for the 200. they're great by the way

[@KincadePavich]

Thanks for the insight - I saw on Slavens that they didn't list the 200 for those bushings so didn't buy them. May end up giving them a shot to see if they work. Will keep an eye on the OEM bushings in the meantime. Thanks!

[@brandob9]

Start that bike when cold with the kicker. The electric isn’t good enough for the heavy duty stuff. I had a 2016 250 with that design and learned it had limits! Let me know if you need some Tokyo off-road bushings.

[@willycarrillo798]

@Kincade Pavich I want cell you a bike ,is this possible ?

[@williamcrotts7054]

How many of you were using spark arrestors?

[@Azbyker43]

Another great video Kincade 👏… I would love to do the same to my 2007 200XC. Parts list?? Tx

[@KincadePavich]

Thank you! It's an enormous parts list, and can only be done if you replace the engine cases too.

[@Azbyker43]

@@KincadePavich After teardown a few months ago I found my case was cracked from a prior crank bearing failure so I’ve been considering replacing the case instead of repairing… at 53yrs old, I think the conversion would be a way to go.

[@Danielwestberry211]

How’d he know I was staring at the air filter😂

[@KincadePavich]

That thing was grimy, I knew you were lookin' at it

[@tomcorle1400]

Pipestone?

[@williamcrotts7054]

Order some extra air filters too.

[@xxshiftlockxx]

Did you ever figure out what the actual growly sound was from your pipe? My bike picked one of those up after dumping it over in Moab. I tried posting all over the place to get ideas but everyone told me I was overthinking things and to not worry about it. It almost sounds like a crank bearing but I'm not sure. Could very well be a vibration too. I put a new gnarly pipe on but the sound never went away.

[@KincadePavich]

For me it was undoubtedly vibration. When I got home and the bike was cool, I held the pipe still while the bike was running. Sound was gone. Did sound like a bad bearing, but was 100% the pipe after I did that test.

[@xxshiftlockxx]

@@KincadePavich Were you able to fix it? or are you just throwing the OEM pipe on instead?

[@pawenawrocik4879]

Hi😊I see that you have 720SBC soft bar clamp! What is your honest opinion about this product? Iam struggling a lot with numbness in my fingers on clutch lever side. Please tell me it is really helpful with vibrations😊 Your videos are great. Thank you for very good content🔥🦾

[@KincadePavich]

It's been awesome - I don't notice any vibration on this bike through the handlebars!

[@levilehman4629]

Hey Kincade, wondering if you have any recommendations for 125 two stroke bikes. In your experience, which makes/years have you seen issues with and which have you been pleased with from not only a riding performance standpoint, but also to build and maintain? Looking for something to ride XC type trails with. Thanks for any input!

[@levilehman4629]

Ps sorry for the overly broad and beat to death “which bike should I buy” question. I just wanted to ask you specifically because of your wealth of knowledge about building bikes and ripping them!

[@KincadePavich]

Hey man! Really any old 125 carbed 2 stroke will be solid and easy to work on. YZs probably have the best parts availability!

[@levilehman4629]

@@KincadePavich yeah… I ended up buying a $600 dollar 98 RM 125 basket case and parts are proving to be difficult to source already… haven’t even split the cases yet.

[@Yz85BWBOY]

Your bike seems like your power band chocking

[@Jacob-kp1bu]

When I order anything off of rocky mountain do you get a commission? Or is it just the link on the description?

[@KincadePavich]

Anything on Rocky Mountain as long as you click that link at some point!

[@Ridefastorgetpassed]

I think the start button is supposed to on the throttle side of the bars .

[@KincadePavich]

The throttle assembly is wide. More comfortable on the left on this bike.

[@Ridefastorgetpassed]

@@KincadePavich I hear ya just dont hit the starter by mistake. Sweet 200 BTW we have an 09 my son rides its like people forgot how awesome they are until the kids kickin their butts on the single track stuff.

[@averykienbaum2904]

What year did KTM swap the 200 to the bigger frame? Wasn't it 09?

[@nevadahardenduro]

Yes

[@kindnuguz]

So is the KTM 300 XC-W HARDENDURO a good bike for what he is doing or would it still need mods? I know that's a $13k bike but time and effort and parts at least with cars always ended up about the same as buying new vs old and modifying it. If one thing I learned from modifying cars / adding turbo, building the engine etc. Factory built all around is far more reliable. I would be highly interested in Pavich adding all parts and rough estimate of time ($75-100 per hr?) and the bike and see if it would be close to 10-13k, I know spending over time is different but if my theory is correct it would be close.

[@Dirtbikeguy-lz7hh]

If you are interested in getting a Ktm 300 I would suggest buying a good condition used one on marketplace for 6~7k instead of a 12k new one but yes it’s designed for exactly what he is doing

[@zachcummings8880]

How much did all the components cost

[@KincadePavich]

Somewhere around $1500... Not cheap.

[@jacemelder2354]

@@KincadePavich would you mind listing g everything out? Wanting to do this to my 2006 as well..

[@petepedro350]

Damn I got tired just watching that enduro run

[@roadtigerplayz]

my mom has one that needs work, iv never even touched a car, so i truly have no idea what im doing, but i want to try dirt biking so bad! i just need money for parts now and to learn lmao

[@DerbiiRaCer]

Hope it holds together for long. This kind of E-Start setup was very unreliable in the long run on the ktm´s from 2008-2015 with the Bendix design.

[@lugnutgarage]

Once your done with it I’ll take it off yours hands for $20 and a new fender for the fender boys

[@shawnbarber5356]

was interested how he would pull it off lost interest once he said he had to buy new cases

[@Paolo-xr7zf]

First

[@elicrabb3663]

pin me