ITALKIT Top End Gasket Kit for KTM EXC 200, SX 200, XCW 200 2003-2016

On KTM EXC 200, SX 200, XCW 200 from 2003 to 2016, the ITALKIT VJ860VG810319 top end gasket kit fits in place of the original part. As soon as the cylinder head or cylinder is removed, their gaskets must be replaced: crushed when tightened, they have taken the shape of the parts and will no longer seal. This kit groups under one part number the gaskets needed to reassemble the top end.

Specifications

• Brand: ITALKIT
• Manufacturer part number: VJ860VG810319
• Engine: 2-stroke

When to replace it?

• Coolant or oil seeping at the head/cylinder or cylinder/crankcase joint.
• Coolant level dropping, bubbles in the radiator.
• Hissing or black marks where the exhaust leaves the cylinder.

At every piston change and every time the cylinder head or cylinder is removed, even for a simple inspection. Gaskets cost little compared with the work of stripping the engine.

Fitting tips

1. Clean the gasket faces without scratching them (plastic scraper, solvent): they must be clean, dry and free of burrs.
2. Fit the gaskets dry, without sealant, unless the workshop manual says otherwise.
3. Refit a base gasket of the same thickness as the old one, unless you are deliberately adjusting the squish.
4. Tighten the cylinder head in a criss-cross pattern, in several stages, up to the manufacturer's torque.
5. While it's apart, replace the spark plug and refill the coolant.
6. After break-in, check the torque with the engine cold and make sure there are no leaks.

Why ITALKIT?

ITALKIT is a Spanish manufacturer of engine parts for small-displacement machines: cylinders, pistons, crankshafts, reed valves and spare parts in several sizes. The brand is very active in 50cc racing, especially in Spain.

Spare parts and items to plan

• Piston : ATHENA · VERTEX
• Piston rings : PROX · VERTEX
• Spark plug : NGK
• Coolant : LIQUI MOLY 1 L · TWIN AIR
• 2-stroke oil : LIQUI MOLY 1 L · MOTUL 1 L

Frequently asked questions

What does the kit contain?
Depends on the model. Compare with your original gaskets if in doubt.

Should I replace it along with the piston?
Yes: as soon as the cylinder head and cylinder are off, new gaskets go back on. It's the right time to fit a new piston kit and new rings if the engine has some hours on it.

Compatibility

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

Fits:
KTM EXC 200 2016
KTM EXC 200 2015
KTM EXC 200 2014
KTM EXC 200 2013
KTM EXC 200 2012
KTM EXC 200 2011
KTM EXC 200 2010
KTM EXC 200 2009
KTM EXC 200 2008
KTM EXC 200 2007
KTM EXC 200 2006
KTM EXC 200 2005
KTM EXC 200 2004
KTM EXC 200 2003
KTM SX 200 2016
KTM SX 200 2015
KTM SX 200 2014
KTM SX 200 2013
KTM SX 200 2012
KTM SX 200 2011
KTM SX 200 2010
KTM SX 200 2009
KTM SX 200 2008
KTM SX 200 2007
KTM SX 200 2006
KTM SX 200 2005
KTM SX 200 2004
KTM SX 200 2003
KTM XCW 200 2015
KTM XCW 200 2014
KTM XCW 200 2013
KTM XCW 200 2012
KTM XCW 200 2011
KTM XCW 200 2010
KTM XCW 200 2009
KTM XCW 200 2008
KTM XCW 200 2007
KTM XCW 200 2006