ATHENA Connecting Rod Kit + engine gasket kit for KTM EXC 250 2003-2006

On KTM EXC 250 from 2003 to 2006, the ATHENA PB322079 connecting rod kit fits in place of the original part. Between the piston and the crankshaft, the connecting rod takes every combustion and every climb through the revs. Replacing the rod, crank pin and bearing in time prevents engine failure.

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: PB322079
• EAN code: 8052780274906
• Weight: 1.27 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?

Founded in 1973 near Vicenza, Athena is an Italian engine gasket specialist that has made its gaskets on its own production lines since day one, as well as a renowned manufacturer of pistons and cylinder kits. The brand supplies original equipment to manufacturers such as KTM, Ducati, Fantic, Piaggio and Triumph, and is a partner of the MXGP motocross world championship.

Spare parts and items to plan

• Crankshaft bearings and seals : ALL BALLS
• Gearbox bearings : see the selection
• 4-stroke engine oil : LIQUI MOLY 10W40 1 L · MOTUL 10W50
• Spark plug : NGK · NGK 13 g

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:
KTM EXC 250 2006
KTM EXC 250 2005
KTM EXC 250 2004
KTM EXC 250 2003