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ktm 200 exc head gasket question

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I am rebuilding the top end on a 2003 ktm 200 exc. The head had 1 oring and a head gasket? I have the ktm parts book and it has 2 o rings for a head gasket? Why would this one have a gasket? For the larger o ring I would think there should be a groove for the o ring to sit in. The top of the clyinder is flat where the o ring should be.

Another question is how thick should the base gasket be? Everything I have read says measure the old one. how do you get an accurate measurement from a smashed gasket? Plus I would think that would change because of the gasket on the head?

THis is the 1st ktm I have had apart, any help would be great.

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My 2000 200 had 1 oring and a gasket. The oring goes into the recess in the cylinder and the gasket goes on top. I think the oring seals the cylinder and the gasket seals the water jackets. If you read the manual it talks about the Z dimension, the distance from the top of the piston to the cylinder. This is adjusted by base gaskets. There are a multitude of topics on this. This is my first KTM also and it was weird to have different base gasket thicknesses also.

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the older KTM's like the guy's before me did use an oring and a gasket. However I think 01 was the last year for that and yours did not use the gasket just two orings. Maybe you have the wrong kit but I think most kit's come made for both models meaning they have both orings and a gasket, you just use what you need.

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The 02's had them also (o-ring+gasket) Yours may just be one they carried over. No performance difference.Just get a head gasket and o-ring and you're good to go.I've rebuilt several of these and they're solid.

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I guess it could be possible for someone to put an older head and cylinder on it? I have the original parts book and I looked on the parts fisch and it is supposed to have 2 o rings. I guess I will have to order a gasket for an older ktm. thanks

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I have seen the 2003 with either design, I have a 2002 and 2009 in front of me..

The X dimension is a tad different but a .4mm base gasket should work fairly well and give good bottom, You can measure the X dimension on the gasket style head motor.. you can go a few thousands tighter as it helps combustion and low speed response.

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