These are two methods for removing the circlips. KTM circlips are burly and take some force to remove. Remember to
stuff a rag in the crank area; dropping a circlip into the motor
is a big bummer.
The letters on the new rings
face up. Slide the rings on and
make sure they line up with the
locator pins on the piston.
With burly circlip rings like the KTM, we like to install one on
the bench. Be very careful not to gouge the piston. We prefer
the method of sliding the piston into the cylinder up to the
wrist pin so we don’t have to try and line up the piston,
squeeze the rings and fit the cylinder on the bike. With the
piston in the cylinder, we only have to line up the piston with
the rod and slide the wrist pin through the rod, then install
the last circlip. Don’t forget to carefully clean off your old
base gasket and install your new base gasket.
your way criss-crossing the
of torque. Make
sure the piston
moves freely up
and down in
If your O-rings don’t lay flat, do like we did and lay them in
the sun for a few minutes to soften them up, or use a hair
dryer or heat gun to warm them. Don’t melt them.
Lay the head on and criss-cross to about 18 foot-pounds of
torque. You are almost done and are a world champ in our book.
Before reconnecting the powervalve linkage, slip the gasket
back on. It wedges behind the rubber boot like shown. Once
the rod is back over the ball, reinstall the little half-circle clip.
Make sure it runs through the tiny little hole before clicking
over the rod. Finish hooking up all the stuff you took off, fire
it up and break it in. You have a lot of riding ahead of you. ❏