PROX Piston Kit for KTM EXC 200 1998-2016

On KTM EXC 200 from 1998 to 2016, the PROX 01.6249.D piston kit (Ø 63.97 mm) fits in place of the original part. At the heart of the top end, the piston soaks up the heat and pressure of every explosion. As it wears, the rings no longer seal against the cylinder: compression drops, power drops with it, and the risk of seizure goes up.

Key features

• Made mainly in Japan, by OEM manufacturers (ProX catalogue).
• Complete kit: piston, rings, pin and circlips.
• Compatible with stock coated (Nikasil) and sleeved cylinders. Not suitable for chrome-plated cylinders.
• Diameter classes to the hundredth of a millimetre for a precise piston-to-cylinder clearance.

Specifications

• Brand: PROX
• Manufacturer part number: 01.6249.D
• Size: D (check that it matches your cylinder)
• Piston diameter: 63.97 mm
• Weight: 280 g
• Engine: 2-stroke

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 20 to 40 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 PROX?

ProX Racing Parts has been supplying engine and clutch parts to motocross riders since 1975, from its headquarters near Amsterdam. According to its catalogue, most of its parts are made in Japan, by manufacturers that also produce parts for the Japanese motorcycle makers.

Spare parts and items to plan

• Piston rings : WOSSNER · PROX
• Piston pin : WOSSNER
• Top-end gasket kit : TECNIUM · CENTAURO
• Small end needle bearing : NTN · ATHENA
• Spark plug : see the selection
• Coolant : LIQUI MOLY 1 L · TWIN AIR
• 2-stroke oil : LIQUI MOLY 1 L · MOTUL 800 1 L

Frequently asked questions

Does the kit include the gaskets?
No: the kit contains the piston, rings, pin and circlips. Add a top end gasket kit, because a head or base gasket can never be reused.

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:
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 EXC 200 2002
KTM EXC 200 2001
KTM EXC 200 2000
KTM EXC 200 1999
KTM EXC 200 1998