The Quest For Horsepower Series Brings You…

1999 KTM 200 Performance Tuning And Engine Building Secrets Revealed

Learn the secrets, what works and what doesn't.

Carburetor Modifications And Swapping

Reed Valves AndPedals

Epoxy Filler

Intake Track Mods And Matching

Head Mods

Cylinder Mods And Porting

Pistons Rings

Crankcase Volume And Matching

Exhaust

Power Valve

Pipes And Silencers

Fuel High Octane Race Fuel And Regular

Bearings

The project bike is a 1999 KTM 200 MXC but the principles and techniques apply to most 2 stroke motorcycles and ATVs as well as other 2 stroke engine applications.

This article is a work in progress. The ebook with pics, video, resourses and information will be ready soon.

Secret Horsepower Tips!
"I did the work myself. The centerline mismatch is NOT where I focused. There is a consistent mismatch in all cases between the cylinder and the case at the rear boost port, and at the transfers. I also smoothed the sharp edges between the intake passage and the transition to the transfers. I put a window in the piston that lines up with the boost port to aid mid-range and up. I also drill lube holes in the piston to cool the cylinder wall between the main exhaust and sub-exhaust ports I do not change the port dimensions of the cylinder, other than raising the roof of the exhaust port to match the exhaust valve. I clean up the transfers, and spend a lot of time smoothing out the exhaust tract out to the pipe flange.The most radical mod is to shorten the rear cylinder skirt to provide better high-RPM flow.This makes it slightly harder to re-install pistons, but doesn't seem to hurt piston life. I lower the deck height with thin base gaskets, then cut the head and reshape the bowl for minimum piston clearance and more compression. I run the NOZH needle, #7 slide and it runs well at 2,000 feet up on PUMP GAS. The motor has run for a year, recently blew the tranny, ( for the second time) and finally replaced the stock piston ( which looked fine) The motor has the same characteristics as before, just more everywhere! Even though I weigh 220, it easily runs with or away from 250's on my MX track.( I attached a pic of the track for comparison) I have a 520 mxc that I consider the finest machine I have ever owned, the 200 is easily the second best. It is a wonderful do all bike. I even tried a 12 ounce Steahly flywheel on the 200 mxc and it hardly slowed it down."