ATHENA Cast Piston for KTM SX 65, XC 65, HUSQVARNA TC 65 and GAS GAS MC 65 2009-2026

On KTM SX 65, XC 65, HUSQVARNA TC 65 and GAS GAS MC 65 from 2009 to 2026, the ATHENA cast piston (Ø 44.96 to 44.99 mm depending on the size class) fits in place of the original part. Made from cast aluminium, this piston takes every combustion and passes it on to the connecting rod. Cheaper than a forged piston and fitted with a tighter clearance, it is very well suited to leisure riding, as long as you replace it at the recommended intervals.

Specifications

• Brand: ATHENA
• Manufacturer part numbers: S4C04500002A, S4C04500002B, S4C04500002C, S4C04500002D
• Engine: 2-stroke
• Piston diameter: A = 44.96 mm, B = 44.97 mm, C = 44.98 mm, D = 44.99 mm
• Available versions: A: ref. S4C04500002A; B: ref. S4C04500002B; C: ref. S4C04500002C; D: ref. S4C04500002D
• Weight: 100 g

Choosing the right size class

The letters A, B, C… are very close diameter grades, one hundredth of a millimetre apart. Measure the cylinder bore with a bore gauge (diameter, ovality and taper) and choose the grade that gives the piston-to-cylinder clearance specified by the manufacturer. As a rule, grade A goes into a new or reconditioned cylinder, grade B into a cylinder that has already been run in. A scored or out-of-spec cylinder has to be reconditioned: you don't make up for its wear with a bigger grade.

When to replace it?

• Loss of power, sluggish pick-up, harder starting: compression is dropping.
• Piston slap on a cold engine, getting more and more noticeable.
• On teardown: vertical scoring on the skirt, stuck or worn rings, thick carbon on the crown.

Replace the piston as set out in your bike's service manual, sooner if you race, and straight away as soon as these symptoms appear. As a Cross-Mania guideline, plan for a new piston every 15 to 30 hours of engine running depending on whether you race or ride for fun. Always measure the cylinder at the same time: a new piston in an oval cylinder won't last.

Fitting tips

1. Clean the cylinder and check it: diameter, ovality, taper and condition of the bore coating.
2. Check the end gap of each ring in the cylinder against the figures in the manual or the manufacturer's instructions.
3. Fit the rings with the mark facing up and each gap correctly located on its locating pin.
4. Check the small-end needle bearing and the pin: at the slightest play, tight spot or marked needle, replace the bearing.
5. Fit the piston with its arrow pointing to the exhaust side, oil the pin and the small end, then fit the circlips without distorting them, gap opposite the notch. A circlip that has been taken out is replaced with new piston pin circlips, never refitted.
6. Reassemble with a new top end gasket kit and tighten the cylinder head in a criss-cross pattern to the manufacturer's torque.
7. Refill the coolant and fit a new spark plug.
8. Break the engine in: warm it up gently, vary the revs and avoid sustained full throttle for the first hour.

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

• Piston rings : WOSSNER · PROX
• Piston pin clips : WISECO · VERTEX
• Top-end gasket kit : ATHENA · PROX
• Small end needle bearing : ATHENA · PROX
• Spark plug : NGK LR8B · NGK
• Coolant : LIQUI MOLY 1 L · TWIN AIR
• 2-stroke oil : LIQUI MOLY 1 L · LIQUI MOLY 4 L

Frequently asked questions

Does the piston come complete?
Yes: piston, pin, circlips and ring(s). The top end gasket kit has to be ordered separately, because a head or base gasket can never be reused.

Which size should I order?
Measure your cylinder: A, B, C, D correspond to different actual diameters (44.96 to 44.99 mm). Choose the class that gives the piston-to-cylinder clearance specified by the manufacturer.

Can I replace just the rings later?
Yes, as long as the piston and cylinder are still within tolerance. Replacement rings can be ordered on their own, as can the piston pin and the circlips.

Should I replace the small-end needle bearing?
It isn't included. Check it at every piston change and replace the needle bearing at the slightest play or tight spot.

Compatibility

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

Fits:
GAS GAS MC 65 2025
GAS GAS MC 65 2024
GAS GAS MC 65 2023
GAS GAS MC 65 2022
GAS GAS MC 65 2021
HUSQVARNA TC 65 2025
HUSQVARNA TC 65 2024
HUSQVARNA TC 65 2023
HUSQVARNA TC 65 2022
HUSQVARNA TC 65 2021
HUSQVARNA TC 65 2020
HUSQVARNA TC 65 2019
HUSQVARNA TC 65 2018
HUSQVARNA TC 65 2017
KTM SX 65 2026
KTM SX 65 2025
KTM SX 65 2024
KTM SX 65 2023
KTM SX 65 2022
KTM SX 65 2021
KTM SX 65 2020
KTM SX 65 2019
KTM SX 65 2018
KTM SX 65 2017
KTM SX 65 2016
KTM SX 65 2015
KTM SX 65 2014
KTM SX 65 2013
KTM SX 65 2012
KTM SX 65 2011
KTM SX 65 2010
KTM SX 65 2009
KTM XC 65 2014
KTM XC 65 2013
KTM XC 65 2012
KTM XC 65 2011
KTM XC 65 2010
KTM XC 65 2009