Installing The Cylinder; Checking The X-Distance - KTM 50 SX 2010 Repair Manual

30/ASSEMBLING THE ENGINE

Installing the cylinder

17.25

Checking the X-distance

17.26
Info
The X-distance is the distance defined for the piston protrusion, when the cylinder is clamped down and the piston is at top
dead center.
The X-distance must be checked very carefully. If the X-distance is too large, the compression decreases and the engine loses
power. If the X-distance is too small, the engine knocks and overheats.
–
Slide piston pin
300466-11
–
Position the piston pin retainer in the 6 o'clock or 12 o'clock position.
–
Ensure that the piston pin retainer is correctly seated on both sides.
–
Remove the cloth.
400541-10
–
Position the new cylinder base gasket.
Info
If neither the piston, cylinder, crankshaft or engine case need to be
changed, the same gasket thickness can be used as before.
–
Oil the cylinder and piston.
–
Position the piston ring.
The anti-rotation lock engages in piston ring end
300465-10 –
Slide the cylinder over the piston.
–
Carefully push the cylinder down and ensure that the dowel pins are properly
engaged.
–
Mount nuts
Guideline
Nuts, cylinder base
–
Check the X-distance. (
300464-11
–
Apply special tool
Adjustment gauge (45129006000) (
–
Position the piston at top dead center.
–
Check the X-distance.
Info
The piston should not raise the gauge off of the cylinder.
300502-10
into the connecting rod by hand.

on both sides and tighten in a crisscross pattern.

p. 91)
to the cylinder.

.

M8 20 Nm
(14.8 lbf ft)
p. 142)
91