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.
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 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?
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.
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??
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.
