I Brought My Blown Up KTM 200 Engine Back to Life

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Check out Matt Spears' KZbin Channel: @MattSpears
3D printed clutch pack organizer: / project_ztg
Send me things to try: PO Box 716, Belgrade, MT 59714
KTM 200 build series: • 2006 KTM 200 XC-W Build
Thanks to Millennium Technologies for an incredible job on this crankshaft, cylinder, and head: millennium-technologies.com/
Thanks to ProX for providing a piston for this project: www.rockymountainatvmc.com/pa...
Check out Antigravity batteries for your power supply needs and use code "kp10" for 10% off!
antigravitybatteries.com/ref/68/
Purchase cleaning wheels from Pryme MX:
www.prymemx.com/?ref=kincade
Huge thanks to SXSlideplate for helping me with a skidplate solution for this project! sxslideplate.com/
The SmartCarb is an ultra-efficient, single circuit, mechanical fuel system that increases performance and improves fuel economy: smartcarb.com/
I'm training with MXFitCo and so should you!
mxfitco.com/join-kincade
MX Plastics for all of your plastics needs:
www.mxplastics.com
DeCal Works graphics and seat covers:
www.decalmx.com/
Fast Metric fastener kits:
fastmetricfasteners.com/
I trust NoToil air filters and oil to keep my bike breathing clean:
notoil.com/
Check out Fastway for high quality aftermarket kickstands:
fastway.zone/
I'm utilizing IMS footpegs and a 3.2 gallon oversized tank for this build:
imsproducts.com/
Urmosi soft bar clamps and enduro specific wheels:
urmosi.com/
DSC Motorsports for your suspension service needs:
/ dscmotorsports_evo
The Magura 167 master cylinder made a world of difference in the way this clutch pulls!
magura.com/en/EUR/product/167
Dirt Tricks offers the best sprockets on the market, plus they're made in the USA and backed by an incredible warranty!
dirttricks.com/
Bullet Proof Designs offers high quality protections parts for your dirt bike:
bulletproofdesigns.com/
Shinko Tires are going to help me stay rubber side down and crawl over rocks at Silver Kings!
shinkotireusa.com/
Boycott Loctite and support offroad riding by purchasing Stuck Nutz threadlocker. Use code "KP10" for 10% off your order! stuck-nutz.com/

[@jasonjavelin]

Matt seems like a solid dude!

[@rasmusskinnerup7181]

Definetly, hope to see them collab on more videos 🤞

[@jauken83]

His channel is great, definitely comes across as a good dude that you want to see succeed.

[@mikebilly822]

Matt seems like a solid dude!

[@BeefySweats]

Yeah I rebuilt a ktm 125 and it’s the same motor as the 200 and I was blown away by the primary gear nut and clutch nut torque spec. I was like dear lord even 450s aren’t anywhere near that tight. I hit it with a pneumatic impact and didn’t have any issues

[@masterbeta343]

3 or 4 ugga duggas oughta do it

[@outdoorclips1112]

I really want a Ktm 125, but how many hours do you think I could put on it be for it needs a rebuild?

[@BeefySweats]

@@outdoorclips1112 I really have no idea, I worked on an 05 ish and it wasn’t my favorite bike ever there were a few things that were questionable in quality and made me ask why they would make it that low quality. I did the rebuild for a friend as he locked up the crank so I don’t own one personally and I stay away from them after that experience.

[@sawlgood]

Dude Matt is a homie. I dont think any of us that were saying "go new" right off the bat were assuming anybody at a fab shop would donate well over $1000 worth of time. Stoked

[@Keegan3G]

I’m the guy who built that crank! I also have a ktm 200. love the build, hope she lasts longer this time!

[@user-kp5db1wk6t]

you feel specail dont you

[@krazed0451]

@@user-kp5db1wk6t It's ok to be proud of your work, mate.

[@kenwolfe5697]

@@krazed0451 Yes it is. Looked like new. Great job!

[@Keegan3G]

@@user-kp5db1wk6t I take pride in my work. Simple as that

[@Pelipoikki]

​@@user-kp5db1wk6t You probably are special with that spelling.

[@highlandcycles]

Stoked you have it back together.

[@ODRoach]

The amazing thing is the amount you upload with quality content, doesn't go unnoticed. I'm a garage dweller/tinkerer and couldn't imaging making sure I film everything and then editing it all. Thanks for taking us along for the ride!

[@masond.4931]

Hey kincade, if you cant fit the stator cover over your flywheel weight, i 3d printed a spacer for the same problem on my yamaha.

[@deancooper5513]

Mate the clutch hub nut is ok at 60 ft lb I had this confirmed by Andrew Cooksey as well. The 250 and 300 have theirs at 73 ft lb…80 is heaps!

[@danebrownawell6063]

I’ve had many cases and cylinders welded. Not a problem 🤞🏻. It helps to heat up the case and let it cool down multiple times before you weld it. It helps to “sweat” out any impurities or oil that’s soaked into it

[@highlandcycles]

I never use a holding tool. Impact with plates in place.

[@KincadePavich]

Noted! I'm not super confident in what torque value I'd get out of my little impact, but clearly the holding tool is problematic! Obviously charging system went on the back burner for now, but I'll get back in touch some point soon!

[@RealEliHutton]

Love the video man, Keen to see the bike back ripping the trails!

[@raymayhew4153]

The 200 lives again. Great job, Kincade. Love the videos!

[@Ridefastorgetpassed]

Something tells me that 200 is going to be your favorite bike after you get some time on it .

[@hawkism]

Looking forward to seeing where you both explore mate 👌👌👌

[@XanderSumner]

Your an a roll with the uploads dude keep I’m up I love the videos

[@nitromodel696]

Dude, I'm glad you got it fixed and working. I would have done the same, trying to save the other cases. Love your videos!!!!

[@davidsonneman1121]

That guy and his gold wing. I love that stuff. Good job!!

[@lbeck119]

Heck ya bud!! Love Matt's channel as well.... Maybe he can talk you in to rockin the lucioli tubes on your silver King build.... You will absolutely love them 🤘

[@toreg]

Love the 200, I rebuildt my SX125 to a 200. Excellent power for MX. I raced the vet class, bring what you got. Scored several hole shots against 450’s.

[@tommywallbanger]

I have had 2 KTM 200 SX's. It's an awesome engine. Now I have a 2015 150 SX and I put the 2004 200 SX engine in it because I wanted linkage rear suspension. Awesome bike. I love that 200 SX engine. I have a Pro Circuit Platinum on this engine but my 2003 had the FMF Fatty and that's the better one in my opinion. Don't you love beating bigger bikes? When I rode a KX 125 my favorite thing to do was smoke guys riding 250's, especially after they asked me why I rode that little 125 or why don't you step up to a 250. I'm referring to 250 2 strokes.

[@dirtbikelyfe23]

Thanks for posting these videos have been the main thing ive been watching. I've been stuck in the hospital for about 3 days, and I'm gonna have to stay away or 2 more I was in a dirtbike accident I have a broken middle finger on my left hand and a small minor compression fracture on my t11 and t12 plate on my spine. They said I'm lucky not to be paralyzed. Keep pumping these videos out🤘🏻🤘🏻

[@KincadePavich]

Dude! Glad they're helping you through it and hang in there. Appreciate the support, and best of luck on the recovery!

[@dirtbikelyfe23]

​@KincadePavich Thankyou I had surgery this morning on my finger I have a plate and 2 pins. I'm 17 so I'll most likely heal in like 3 months they siad

[@dragoslavpetrovic3616]

Bravo, svaka čast!

[@rasmusskinnerup7181]

Hell yeah 🤘 would love to see your take on a naked street bike or touring bike build 😎

[@HTAracing558]

I ve been doing about the same break in precedure. 2 heat cycles, or a little up and down the road. First time at the track or trails let is warm up easily when it is hot just give it the beans. Never had any issues. I'm pretty sure it where the cases and the seal.

[@chrisjohncarreon9531]

amazing work man!

[@kenwolfe5697]

Awesome series

[@pjm204]

Since I've watched you break 3 clutch hubs I'll share what I do as someone that has taken down a bunch of engines without breaking one. I use a few of the old clutch plates and steels along with a few pairs of vice grips to make my own clutch tool. The fiber plates may get damaged in the process but it never hurts the steels in case you're reusing them. I just position the vice grips around the circumference evenly pinching the fibers around the steels. Works every time. Great videos and your skills keep increasing. Definitely time to retire that tool though as you said. Sometimes the right tool isn't the right tool 😂

[@PNW_MX222]

It’s easier to just remove the pressure plate, leave all plates in and impact the basket nut off while holding rear brake pedal. Never had to do anything else in 25 years.

[@pjm204]

​@@PNW_MX222he was torquing the nut back on. Unless you're just sending it with the impact to put the nut back on, that doesn't work.

[@PNW_MX222]

@@pjm204never had an issue

[@abritablondeabike]

Love your content dude. Keep it up.👍👍😄

[@sfmountainbiking612]

Hell yea!! Great video as always

[@Unqualified2ride]

Love your stuff homie! Motivates me to film more stuff 🤘🏼

[@averykienbaum2904]

Oh yeah budddy!!!! Can't wait to watch it!!! Let's go! Expensive episode lol but we gonna watch it all let's see boy!

[@Danman1972]

SilverKing entry, gas to get there, hotel and all expenses is likely close to the cost of cases Not to mention the training time invested. Spending the bones is a good thing. Breaking out and tanking the race to a mechanical would be super expensive and you'd spend that money anyway! Those clutch holders deals are slick! That is awesome. Easy to use them to soak plates as well. I'd bet he'd do well selling them. At least pay for his print equipment anyway if he has already not recouped it. I have the EBC laser cut holding tool (works great). It holds all the teeth for the basket or the hub. Also, likely a bit to late, but pretty sure you can use the new "estart" clutch and stealthy FFW. I have that on my wifes 13 200xc-w Same break in for me.... couple of heat cycles. The an easy ride with varied throttle modulation. Try to wide open. Then ride it like normal.

[@robh3267]

The bike definitely sounds better, you should consider sending your head to Kelsey at RK Tek, his head mod will give the 200 much better bottom end with no sacrifice to top or mid range, I've been running 50:1 using top of the line synthetic premix for over 20 years and have never had any failures, whoever did that JB Weld repair job is the reason for your motor issues, it wasn't anything you did, that being said the bottom end of that rod was the worst I've ever seen, now it's going to run like a 200 should, some VForce 3 reeds would improve throttle response and overall performance for not much money but for some reason Rocky Mountain doesn't sell them for full size KTM's but Motosport does, looking forward to your first ride back on it.

[@jamessmith8284]

Just got a 200 last friday, hopefully I wont have these kind of issues but now I know who to go to for parts!

[@outfitr9703]

Nice bulls on the wall! Oh and I'd never say I told ya so but.....

[@vuongchibach8994]

From Vietnam with love 🤠

[@yickyhite1725]

23:56 I always use rocky mtn. Next time ill deffinetly use link. Have a good one m8!!!

[@SirIan-oz1nk]

I like your builds, i do love 2-Stroke engine. By the way Shout out here from Philippines 🇵🇭

[@m.m.aautos6608]

Never seen that one coming! I just found Matt's KZbin last week

[@bve7397]

Ur skills are fasinating too watch

[@enduromachineusa]

Interesting approach to using the Tusk holding tool other than on the basket. I've used the foot brake method with the motor in the bike, so I'm not surprised it worked. However, I must admit, it never occurred to me to take that approach with the engine out of the bike. For what it's worth, I broke my inner clutch basket on my KTM 200 the first time I used the Tusk tool as well. I think the tool is probably fine under most circumstances. However, as you mentioned, the geometry of the alignment on the 200 hub and the basket construction must be an accident waiting to happen. Like you, I ended up buying an OEM replacement basket and, at the time, the EBC clutch holding tool. In hindsight, I probably could have used the method you used in a pinch since I already had the Tusk tool.

[@Mr.Bearded.Mechanic]

If you have a buddy with a laser cutter you can cut any clutch hub holder at any time. Just scribe over the hub on a piece of paper, scan it, or even better if you paper scan the metal clutch disc in any CAD program you can make a sketch, save it in dxf format, and be good to go. You can cut it from aluminium also.

[@phatheadracingmx]

Beautiful shades of blue on that roached main bearing

[@tommywallbanger]

Hey Great Video. I've been riding since 1983 but like riding dirt bikes a lot better than working on them. I've never split a case or done anything more involved than a top end. I have a 2004 KTM 200 SX engine with a case leaking on the right side by my clutch cover in between the kick started and oil fill, that little V there and I'm researching what to do to fix it. It's not a huge leak but it won't go away that's for sure. I doubt the bottom end was ever serviced, I'm not the 1st owner. I've heard just replace the gasket, I've heard don't use a gasket use Honda Bond instead, and I'm torn because I know if I do it myself I'll earn a lot about my bike but I'm also thinking if I have somebody else do it it might be the only time I have to do this. I work a lot and don't have the time. Do I want to spend all my free time working on this and being my 1st time I'll probably make some mistakes and have to go back and do them over again.

[@jacemelder2354]

A video adding estart would be great! I want to do the same with my 06!

[@diyjeff1838]

Eventually you will learn that time is much more valuable than money.

[@ryanwilliams4270]

Agreed. When he dumped 6 plus hours in, I'm thinking of what 6 hours of overtime pays. He paid for the case twice, left that risk analysis out of the video lol. It's an experience and looked like a goodtime with a friend I guess.

[@Jarek_Bielecki]

I was waiting for this episode :)

[@crash86ed]

Watching that clutch hub break was...heart breaking. I have the same tool and have used it on a few bikes. It works *ok* but has always felt sketch. The EBC tool is worth it lol. Could maybe have your buddy make you a tool using an old clutch disk?

[@KingofKahkis]

I would’ve torqued the clutch nut with the engine installed. Use the chain to hold the countershaft sprocket via locking the rear wheel.

[@th1npower]

.. Kincade, I have a 2nd primary gear that sits bw the primary and gear hub when I torque it... fits great! If you need it in the future, it's a great problem solver! I've had the same issue with the Tusk hub holder, so I quit using it a long time ago ...

[@KincadePavich]

Unfortunately a 2nd primary used as a fear jammer does not lock the inner clutch hub - only the primary and clutch gears. Unless I'm misunderstanding the way you use it? The inner hub would still spin

[@wadebarone8285]

Electric start is worth its weight in gold on the side of a mountain!

[@onthethrottle7104]

Agree! I would have chipped out the frozen credit card for that one if I had to. Electric Start for the win!!!

[@Fassfilmz]

What year engine cases did you get

[@nick0002nick]

Loving the build. I have an 01 200exc and it is the perfect bike for me but I wish it had electric start. Would love to see a video on it. Can you say what year cases they were? Iv looked at ktm dealer pages and it looks like the 2013 matches them. But the cases alone are $1800 here in australia if they are the 2013 ones

[@KincadePavich]

Yes these are the 2013 150 cases. Part #52430000033

[@vhjvbhjb5280]

You only use the clutch holding tool when torquing right? I've always just threw the clutch plates in and zapped it with a low power impact tool, cause i've always had the fear that, something like that would happen.

[@TheNolannn]

Just a thought. Leather belt/ dog leash. Wrap around the inner hub and through the basket. Same as persay an oil filter strap wrench. Have done it on many bikes

[@MrAndyloz]

You handled that clutch holding tool well. I'd launch it across the workshop

[@jakobostan8058]

hey i have a question so i want a dirtbike and i dont have the money i relly want 125 cc but i have only 1100 and the chepest is 2400 and i have a moped and doesnt work propely and it brokes every week

[@user-wu8ib1je3j]

Is it the same break in for a 4 stroke

[@scottnilsen7285]

Hey mate love the channel just curious on your thoughts on fuel filters on two strokes. My belief is that it would change the ratio of oil to fuel. I like the idea and use fuel socks.wondering what your thoughts are. Keep up the good work.

[@KincadePavich]

SmartCarb recommends a fuel filter. I don't think I'd be worried about it changing the ratio. Both fuel and oil particles are small enough to flow through no problem.

[@justingardner3569]

My break in procedure for my 30+ bikes/rebuilds over the last 19 years of riding/racing is 2 heat cycles followed by hard motos and oil change after the first ride for 4 strokes, 2 strokes get 2 heat cycles followed by even harder motos. Other than the forged pistons I’ve used, those get a couple more heat cycles. NEVER had a bike blow up or any major failures other than my 105sx and 144sx which were just doomed by design. I think break in period is a bit silly for dirtbike engines, but that’s just me!

[@larrywarner9314]

Now old school guys will mix up one gallon mixed at 28:1 and do 5 heat cycles then putt around until the gallon of fuel is gone then mix up some 32:1 fill the tank and go for a ride and then hammer time brrraaapppp

[@BadMooseRecords]

Hey. I have made an clutch holding tool from the old clutch steel plates. Take them to your friend and make him weld them together with the tig for free. And force him to make a handle for them and weld it to the plates. Then go and pay the 6 hours for the alu weld to the guy. 🙂 All so a leather oil filter change strap thing works for holding the clutch. Remember to take the broken one with you to the welding guy so you can line up the disks.

[@Matthew-wn8oq]

That sounded really good. Break in "procedure " is a bunch of crap. You just give it a couple of heat cycles and then ride it.

[@paytonemmons4952]

Wooohooo!

[@alexhill_79]

Bloody oath love the content

[@timofeypinchuk877]

How heavy is your flywheel weight?

[@Ricky1988blizzy]

Hey bro net time u mix ur gas pour a little bit of gas in your mixing cup and swish it around to get all of your oil out

[@nuttynick1305]

What fuel tank do you have in this thing ??

[@PNW_MX222]

I like that you’re going richer on metering rod. Most don’t really get the concept that going from 50:1 to 40:1 actually creates a leaner fuel to air ratio. This is because there is now less fuel (due to more premix) per ounce going to the motor with same amount of air as it did at old ratio. I’m sure you know that, but some other viewers might not.

[@richardstewart5095]

Oil will also combust inside the engine so that is not the only factor in play here. You also have to take into account the greater viscosity of the fuel mix and the difficulty of the fuel mix to be sucked through the jets or whatever the fuel opening is called on the smart carb.

[@jesse.jsmall0652]

That guy lives in reality had me 🤣☠️

[@Elliott_Ray]

Bikes great and great video!! But for real…WHAT’s YOUR WORKOUT ROUTINE? those arms be shredded while you shaking that pre mix

[@KincadePavich]

Haha I'm doing the MxFitCo regimen!

[@pisgahwrestler119]

Hanging with a buddy and trying something is far superior to waiting on FedEx.

[@glacierfinancial]

Hi guys, I have a KTM 200 2 stroke that I love. I blew up the transmission this weekend, is it worth rebuilding the transmission or should I part the bike out?

[@KincadePavich]

Rebuild the transmission

[@paulbudford]

That's a shame the engine case welding didn't work. Had to give it a try though.

[@xxshiftlockxx]

What made you decide to run 40:1? Genuinely curious, as the owners manual for my 2012 200 is 60:1

[@KincadePavich]

The manual for this bike says to run anywhere from 40:1 to 60:1, and I wanted a little more safety in extra oil lubrication in the crankcase

[@xxshiftlockxx]

@@KincadePavich makes sense! Thank you. Good luck with this one man. These videos are sweet, and making me crave riding my 200 BAD! lol.

[@107Anderson]

MORE OF U THIS GUY ON UR CHANNEL PLEASE

[@ronlawson5819]

Not for nothing….having a friend with those skills is priceless

[@richardvollmer2842]

Not sure what injury you have on your hand but sounds like a metacarpal fracture, i had the same problem after getting my hand slammed in a car door, would swell up everytime i rode especially when i did enduro. But would be perfectly fine every other moment of the day. Would recommend getting a xray because improper healing for it can cause permanent weakness in grip

[@KincadePavich]

I did get it x-rayed, nothing broken. Going to try acupuncture for the first time ever later today.

[@richardvollmer2842]

@@KincadePavich goodluck dude! Hope you feel better

[@JaxsonM22]

Got me feeling nervous for my first full motor rebuild.. there’s alot more to it then I thought.

[@krazed0451]

Looked like some decent welding results at first, I can't believe how ready people are to throw $600 at a problem that will likely be solved with repair. I hope you gift Matt something nice for his trouble :-) You know what holds a sprocket better than anything else? A chain xD

[@ronlawson5819]

Dude if you can swing it……the E start before silver kings

[@IAmPiernik]

Love the video!! Loads of creators are like oh I bought a few bits for the bike! Like 3-4 k worth of stuff and it's like... That's nice the rest of us are poor 😂

[@patpaluch9842]

I have a manual for 2012 XCW series and the torque spec for the clutch nut really is that high for the KTM 200. Strange because you flip over a page to a section with KTM 300 torque specs and it’s 100Nm rather than 130 Nm. Also the 200 uses 243 loctite vs 648 for the 300. Strange that the 300 requires less torque than the 200!

[@shaneroberts440]

What brand 1/4in. torque wrench do you use?

[@KincadePavich]

Honestly it's a cheapie I got an Amazon years ago

[@jcalloway1]

Hey Kincade, I am actually doing a supermoto build with the same bike. The exact year. I have everything I need to start the build. However, there is a small crack in the left case that I repaired. I also have been trying to figure out a way to add e-start. I called Rocky Mountain ATV, but they said that the part number in your video was a restricted item they couldn't sell me. Can you provide the specifics of the part number for that case? I would really appreciate it. Appreciate the content. I enjoy your videos.

[@KincadePavich]

Part number is 52430000033!

[@gamerguy2159]

Where do you find your manuals for repair?

[@KincadePavich]

Google search or Ebay

[@Ernbern124]

Dude the Goldwing guy! Hahahaha love that guys videos. Thought he was crazy for the shit he did on that goldwing. Half the episode felt like I was at the dentists office.

[@KincadePavich]

Do you like the dentist's office? Hahaha. And yeah, he is crazy! And a hell of a rider.

[@Ernbern124]

Hahhaha no. Glad it’s not me getting a filling or some shit. Dude for real!

[@kriskingsmore]

Watched this Two days ago. Blew my 200 up the next day. I blame you! Lol

[@wyattpeterson4892]

I have a 2008 yz450f with a shot engine but good bike want to buy it and fix it up?

[@KincadePavich]

No thank you!

[@garrettholden7784]

The shane gillis reference was recognized hahah

[@HuntersHouse-ge2xz]

what 2 stroke oil do you use?

[@KincadePavich]

Currently Yamalube

[@guyonthecouch136]

My friend cooked his 08 rm250 2t and it blew a hole out the bottom, the bike shop said throw the engine away?! We got it welded up and it is now one of the best motocross 250s I've ridden.. Always try weld first

[@wyattpeterson4892]

Kincade I have a 2008 yz450f with a blew engine the rest of the bike is in good shape wanna buy it? I live in South Dakota

[@RollForever88]

Man, I wish I had this kind of skill to work on and rebuild a bike. I suppose you just start somewhere and figure it out?

[@MikeyMcRider]

Yup It's kind of like mounting your first women!!!

[@Jacob._.W5789]

*cracked case and leaking seal “Yup def the carb and break in” People crack me up 😂

[@tivancloete6960]

I recomend using a air impact or a torque wrench. The one your using is not very safe as it is unpredictable.

[@m.m.aautos6608]

Holy moly, you use to run 50:1? , a while back my bike loved 32:1 🤙🏽🤙🏽🤙🏽🤙🏽

[@KincadePavich]

I follow KTM's recommendations. I run 32:1 in everything Japanese!

[@poof1907]

question. if i get a brand new 450 and 5th gear pin in as soon as i get home will that blow it up or is that all bogus

[@KincadePavich]

It might blow up. If you did that on a 2 stroke, it would almost certainly blow up.

[@poof1907]

@@KincadePavich yeah kinda figured. how would you break in a 4 stroke?

[@Pittsburgh-412]

Wow that is unbelievable that broke again. I've never seen that before 😂

[@ODRoach]

Holy crap that hub torque spec is either wild AF or wrong LOL.

[@bobbyburnah8106]

I put 30:1 and ride it like hell for that gas tank never failed me yet😂