METEOR Piston Kit for YAMAHA YZ 80 1993-2001

On YAMAHA YZ 80 from 1993 to 2001, the METEOR piston kit (Ø 45.95 to 45.98 mm depending on the size class) 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

• Italian piston manufacturer since 1952.
• Complete kit: piston, ring(s), pin and circlips.

Specifications

• Brand: METEOR
• Manufacturer part numbers: PC1568A, PC1568B, PC1568C, PC1568D
• Piston diameter: A = 45.95 mm, B = 45.96 mm, C = 45.97 mm, D = 45.98 mm
• Available versions: A: ref. PC1568A; B: ref. PC1568B; C: ref. PC1568C; D: ref. PC1568D
• Engine: 2-stroke

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 METEOR?

Meteor is an Italian piston manufacturer founded in 1952. Formerly an OEM supplier to Piaggio and Innocenti, the brand now develops pistons for motocross and enduro through its Meteor Racing division.

Spare parts and items to plan

• Piston rings : WOSSNER · WISECO
• Piston pin : WOSSNER
• Piston pin clips : WOSSNER
• Top-end gasket kit : ATHENA · INNTECK
• Small end needle bearing : NRB needle cage 12x17x14,2 for HONDA M… · ATHENA
• Spark plug : NGK 6801 · NGK 3530
• Coolant : LIQUI MOLY 1 L · TWIN AIR
• 2-stroke oil : LIQUI MOLY 1 L 3065 · LIQUI MOLY 1 L 3063

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.

Which size should I order?
Measure your cylinder: A, B, C, D correspond to different actual diameters (45.95 to 45.98 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:
YAMAHA YZ 80 2001
YAMAHA YZ 80 2000
YAMAHA YZ 80 1999
YAMAHA YZ 80 1998
YAMAHA YZ 80 1997
YAMAHA YZ 80 1996
YAMAHA YZ 80 1995
YAMAHA YZ 80 1994
YAMAHA YZ 80 1993