ATHENA cast piston Top End Kit (Piston + Gaskets) for KTM SX 85, XC 85 and HUSQVARNA TC 85 2003-2017

The ATHENA piston + gasket top end kit (Ø 46.94 to 46.97 mm depending on the size class) is designed for KTM SX 85, XC 85 and HUSQVARNA TC 85 from 2003 to 2017. This kit brings together under a single part number everything you need to rebuild a top end: the complete piston (rings, pin and circlips) and the top end gasket kit. No forgotten gasket, no second order: everything is matched to the same engine.

Specifications

• Brand: ATHENA
• Manufacturer part numbers: P4C0470013005A, P4C0470013005B, P4C0470013005C, P4C0470013005D
• Engine: 2-stroke
• Piston diameter: A = 46.94 mm, B = 46.95 mm, C = 46.96 mm, D = 46.97 mm
• Available versions: A: ref. P4C0470013005A; B: ref. P4C0470013005B; C: ref. P4C0470013005C; D: ref. P4C0470013005D
• Weight: 350 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. Use the gaskets supplied in the kit, fitted dry, 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?

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

• Piston rings : ATHENA · PROX
• Piston pin : WISECO · WOSSNER
• Piston pin clips : WISECO 125 L
• Small end needle bearing : PROX · ATHENA
• Spark plug : NGK 2707 · NGK 3006
• 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?
The complete piston (rings, pin and circlips) and a top end gasket kit. The small-end needle bearing is not included.

Which size should I order?
Measure your cylinder: A, B, C, D correspond to different actual diameters (46.94 to 46.97 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:
HUSQVARNA TC 85 2017
HUSQVARNA TC 85 2016
HUSQVARNA TC 85 2015
HUSQVARNA TC 85 2014
KTM SX 85 2017
KTM SX 85 2016
KTM SX 85 2015
KTM SX 85 2014
KTM SX 85 2013
KTM SX 85 2012
KTM SX 85 2011
KTM SX 85 2010
KTM SX 85 2009
KTM SX 85 2008
KTM SX 85 2007
KTM SX 85 2006
KTM SX 85 2005
KTM SX 85 2004
KTM SX 85 2003
KTM XC 85 2012
KTM XC 85 2011
KTM XC 85 2010
KTM XC 85 2009
KTM XC 85 2008