TWO-STROKE HOW-TO DB
QUICK AND EASY
KTM REBUILD If you have an hour, you’re as good as new
The benefits of owning a two-stroke are low-cost maintenance and easy top-end rebuilds. Back in 1981, Tom Webb witnessed Dick Burleson slap new rings in his Husky 250 at a national enduro in
the California desert in between loops to keep it running strong. While we don’t expect you to be able to
accomplish this in your next off-road race, rebuilding a two-stroke top-end in about an hour is a pretty
realistic goal. Here’s Scot Gustafson’s advice on how to rebuild a KTM two-stroke top-end.
Once the bolts are loose, the starter just pulls out. It may
take a little wiggling, but it will pop out.
After the spark plug comes out, then loosen the head bolts.
No time to rest, keep going.
Before you can remove the cylinder, you must disconnect the
powervalve linkage. There is a small half-circle clip that
unclips and drops down. Be careful not to drop it; it’s small,
and if you lose it, you won’t be riding until you get another
one. Once removed, you can pull the linkage arm off the ball.
Now it is easier to get to the cylinder nut. Remove the cover
on the opposite side of the cylinder to get to the other nut.
There are four cylinder nuts.
We recommend rotating the crank so the piston is at the
bottom of the stroke; this will give you enough room to pull
the cylinder off.