Jetting Help with my 2002 KTM 200 EXC

ipaman · 08-24-2010, 07:31 PM

I just picked up a 2002 200 EXC. It is fairly rough, but I know I can bring it back to life. It starts up and idles fine, but when you get on it it hesitates really bad. It has an FMF Pipe and Silencer. It also has some type of aftermarket air filter. I checked the jetting and it appears to be stock:

- Main:178
- Pilot:45
- Clip in 3rd position from the top. - I tried going up one clip and down and it still had a bad hesitation.
- Air/Fuel Screw 1-2 turns out. I tried changing this all over and it did nothing.

I ordered a 175,180, and 182 main. I also ordered a 42 and 48 pilot. I am hoping these will have me covered.

ipaman · 08-26-2010, 06:12 AM

Well, I decided to replace the piston and rings. I took the carb out and decided to check the float level per the instructions in the KTM manual. At 60 degrees my float was not parallel to the carb. It was way too high. I checked it 3-4 times and then adjusted it. I am hoping this was my problem

bajadog · 08-26-2010, 06:41 AM

Sorry for the late response.

This site is highly regarded for it's free jetting advice:

http://www.yellowdogracing.com/techstuff.htm

Hopefully your float level adjustment fixed the problem.

ipaman · 08-26-2010, 06:43 AM

Thanks. I won't know until tomorrow or Saturday, but I think it will. I tried a couple different jets and they didn't change anything. I went one up and then one down on the main with no luck. It was almost as if the bike wasn't reacting to the changes. After seeing how far off the float was I would think that was causing me problems.

ipaman · 08-30-2010, 08:16 PM

UPDATE:

I finally bit the bullet and took my bike to the local KTM dealer. Within an hour and a half they had it fixed. I was jetted way too rich. This was on Saturday. I rode for several hours on Sunday and she ran great.

bajadog · 08-31-2010, 07:05 AM

Glad to hear your bike is dialed in.

Nytrydr · 11-11-2011, 07:21 PM

I have an 02 and run the stock jetting, runs great now. But when I bought the bike it had the same symptoms you described I tried jetting it to no avail it turned out the main bearing seals were bad and it was sucking the tranny oil out the exhaust. I rebuilt the motor and all is well now. What jetting did you end up with from the dealer.

Donn
Northern Ca.

Nytrydr · 04-29-2012, 02:32 PM

What Jetting did you end up with?

Donn