125-200cc Part 2: Installation of the WB165 Kit

[john01]

Any word from FMF? What year KTM 200 pipe do we need?

 

[dartyppyt]

Looks good Matt! Bike looks Sweet!

 

[MattR]

Any word from FMF? What year KTM 200 pipe do we need?

I believe Walt used a 2003-2004 200SX. Hopefully, Walt will chime in.

 

[john01]

Thanks Matt that sound right.

 

[Chris Sykes]

Cracking guide! Your teardown already helped me and this will be getting printed off and used as soon as my piston kit arrives!

Couple of quick noob questions...

Where are the journals that you dropped a couple of drips of oil down? are these the two holes on top of the bottom end? Is 2 stroke ok for this?

How do you lube the big end bearing? just drip a little oil to the side of the conrod?

What and where is the locating pin? I see your new piston ring gap is towards the inlet side, is this the way it needs to go in?

Thanks!

 

[Motosportz]

AWESOME post. Thanks so much for doing that.

 

[MattR]

Cracking guide! Your teardown already helped me and this will be getting printed off and used as soon as my piston kit arrives!

Couple of quick noob questions...

Where are the journals that you dropped a couple of drips of oil down? are these the two holes on top of the bottom end? Is 2 stroke ok for this?

How do you lube the big end bearing? just drip a little oil to the side of the conrod?

What and where is the locating pin? I see your new piston ring gap is towards the inlet side, is this the way it needs to go in?

Thanks!

Yes , you will use your premix oil for the lube. Like you described, I dripped in the spaces along the sides on the conrod. I was more generous than probably needed, but it can't hurt.

The arrow on top of piston points forward to exhaust. This will make the locating pin in the ring slot be on the inlet side. After you put the ring on, you will need to squeeze the ring and keep it centered on the pin as you install the cylinder.

 

[Kevin_TE250]

She’s ready to ride…

. Hey Matt , where did you get the case saver ? Been looking for one for my 04

 

[Kevin_TE250]

Never mind... Went back and read the post.. Custom design.. Nice work !

 

[Blakelpd5]

THANK YOU THANK YOU THANK YOU for the write up!!! I had never been into an engine that far before. It was super simple, I mean really simple with this guide!! Great info on both tear-down, and build... Even though i read about the power valve gasket, I too, put the linkage all back together, then realized I forgot it!!!

 

[meusoc45]

Also, I’m using a KTM junction coupling for a better seal. The Husky coupling leaks too much.


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Hi Matt,
What KTM junction seal did you use, was it for a 200SX model? My Husky seal leaks badly. Thanks, R.

 

[wallybean]

Use the one for the 125/150. It is a tight fit but it never leaks.

 

[meusoc45]

Thanks Walt for getting me squared away. My bike flat rips. Richard.

 

[TROFFER88]

Here is my 165

Ooooops and my new GG

 

[Idacurt]

Is the GG a 300? very nice! how do you like it?

 

[TROFFER88]

250 best bike I have owned period

 

[Blakelpd5]

Sexy bikes Tim**************************************** I dig your style (In a non-gay type of way)

 

[Idacurt]

Does it feel smaller than the 125 when sitting on it? looks slightly more narrow? how does it compare in weight? really looks nice

 

[hammer]

250 best bike I have owned period

My wife rides the same bike and I agree with you. Amazing motor and handling of a 125.

 

[wallybean]

Damn Tim, I swear every bike you own is the the Shitznizzle!