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200exc piston questions
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[QUOTE="overthebars, post: 988434, member: 62187"] Hopefully you can tell me a couple of things concerning a new piston that I got for my bike. I decide to replace the piston in my ’03 200 EXC. The old piston looks to be in excellent shape (as does the bore), but it has 2 seasons of riding on it, and I thought I would be a conscientious owner who changes his piston before it disintegrates along the trail due to old age. I pulled the top end off. The old rings had a gap of .38mm and .50 mm. One was past the wear limit of .40mm. The piston had a “1” stamped on it, so I ordered a type 1 KTM OEM piston set via mail order. It came today, so I went to change it. Before I put it in, I noticed a couple of minor oddities that I thought I might ask about before I finish the installation. First, there is something weird about the little pins that keep the rings in place on the new piston. They are nearly in alignment with each other! There is only a couple of degrees away from being one over the top of the other (maybe 3mm of offset). They are located between the same ports on the bore. My old piston has the ring placement pins more like 20 or 30 mm apart (one on each side of the inlet port). I have never seen a dual ring two stroke piston with the ring gap aligned one over the other like this. Is this a manufacturing screw up, or is it normal? Secondly, my old piston has the exact size stamped on it. It is 63.95mm. It also has a .01+ stamped on it. The new one is stamped 63.94mm. The both mike out to 63.94, but the old one has a lot of miles on it. The rings on the new one have a ring gap of .35mm, which seems pretty close to the wear limit to me for new rings. I bought my bike used. But it was in new condition. The original tires still had the dye streaks that new tires have when I bought the bike. I was told the bike was never torn down. But is this an oversized piston that it had in it? .01mm seems to be too small of an increment for an over-bore. I thought bore were usually in the .1mm increment range. With the plated bore, I would have thought it is not even feasible to bore this bike. I am sure the new piston will work, but if it isn’t correct, I would just as soon send it back for a +.01 piston. Am I worried over nothing? Any insight on this situation? Thanks Tom H :ride: [/QUOTE]
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200exc piston questions
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