ATHENA Connecting Rod Kit + engine gasket kit for KTM EXC 520, EXC 525, SX 520, SX 525, SXS 540 and BETA RR 525 2000-2009

The ATHENA PB322081 connecting rod kit is designed for KTM EXC 520, EXC 525, SX 520, SX 525, SXS 540 and BETA RR 525 from 2000 to 2009. The connecting rod links the piston to the crankshaft and takes the most violent loads in the engine. Its big-end bearing and crank pin wear over the hours: play at the big end is the warning sign of a failure that can wreck the whole engine.

Key features

• High-strength forged connecting rod made in Japan.
• Supplied with crank pin, needle bearing and thrust washers, depending on the application.
• Fits to original dimensions, with no modification.

Specifications

• Brand: ATHENA
• Manufacturer part number: PB322081
• EAN code: 8052780274920
• Weight: 1.16 kg
• Engine: 4-stroke

When to replace it?

• Vertical play at the big end at top dead centre.
• Side play out of tolerance, signs of overheating (bluing).
• Vibration and dull noise from the bottom end.

During a bottom end rebuild, at the intervals in the service manual, and without delay as soon as play appears at the big end.

Fitting tips

1. Replacing a connecting rod means pressing the crankshaft apart and then realigning it: with a dial indicator, you check the run-out, i.e. the deviation in rotation measured at the end of the shaft, which must stay within a few hundredths of a millimetre at most. Leave this job to a properly equipped workshop if you don't have a press and a truing stand.
2. Replace the crankshaft bearings and oil seals at the same time.
3. Check the big-end side play after assembly.
4. Close up the engine with the engine gasket set included in the kit and tighten to the manufacturer's torque.
5. Check the gearbox bearings, then fill up with fresh oil and fit a new spark plug.

Why ATHENA?

Athena, an Italian company founded in 1973 near Vicenza, designs gaskets, pistons and cylinder kits for motorcycles. An OEM supplier to KTM, Ducati, Fantic, Piaggio and Triumph and a partner of the MXGP world championship, it develops its parts on the test bench and on the track with racing teams.

Spare parts and items to plan

• Crankshaft bearings and seals : see the selection
• Gearbox bearings : see the selection
• 4-stroke engine oil : LIQUI MOLY 10W40 1 L · MOTUL 10W50
• Spark plug : see the selection

Frequently asked questions

Is the gasket kit included?
Yes: this kit contains the connecting rod and an engine gasket kit, so you can close up the engine with new gaskets.

Can I fit the connecting rod myself?
Yes, if you have a press and a crankshaft truing stand; otherwise, an engine workshop can do it for you.

What else should I plan for?
The crankshaft bearing and seal kit, the gearbox bearings if required, engine oil and a new spark plug.

Compatibility

Check the exact model and year of your bike in the list below before ordering.

Fits:
BETA RR 525 2009
BETA RR 525 2008
BETA RR 525 2007
BETA RR 525 2006
BETA RR 525 2005
KTM EXC 520 2002
KTM EXC 520 2001
KTM EXC 520 2000
KTM EXC 525 2007
KTM EXC 525 2006
KTM EXC 525 2005
KTM EXC 525 2004
KTM EXC 525 2003
KTM SX 520 2002
KTM SX 520 2001
KTM SX 520 2000
KTM SX 525 2007
KTM SX 525 2006
KTM SX 525 2005
KTM SX 525 2004
KTM SX 525 2003
KTM SXS 540 2005
KTM SXS 540 2004
KTM SXS 540 2003
KTM SXS 540 2002
KTM SXS 540 2001