ATHENA Racing Forged Piston for ATHENA cylinder for YAMAHA YZ 85 2002-2026

The ATHENA Racing forged piston (Ø 52.96 to 52.98 mm depending on the size class) is designed for YAMAHA YZ 85 from 2002 to 2026. A forged piston is made by squeezing a hot aluminium slug in a press, instead of pouring the metal into a mould. The metal is denser and stronger: the piston copes better with high revs and heat, which makes it the choice for racing engines.

Key features

• High-silicon aluminium alloy, forged by reverse extrusion.
• CNC machined to a tolerance of less than 0.01 mm, tested on the bench and on the track.
• Rings made in Japan, with a PVD or chromium nitride coating.
• Supplied with pin, circlips and ring(s).

Specifications

• Brand: ATHENA
• Manufacturer part numbers: S5F05300001B, S5F05300001C, S5F05300001D
• Engine: 2-stroke
• For ATHENA cylinder kit ref. P400485100077 (Ø53 mm)
• Piston diameter: B = 52.96 mm, C = 52.97 mm, D = 52.98 mm
• Available versions: B: ref. S5F05300001B; C: ref. S5F05300001C; D: ref. S5F05300001D

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?

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

• ATHENA cylinder kit : ATHENA
• Top end gasket kit : ATHENA
• Cylinder head and dome : ATHENA S410485308033 · ATHENA S410485308035
• Exhaust power valve parts : ATHENA
• Cylinder kit bolt kit : ATHENA
• Small end needle bearing : ATHENA · PROX
• Spark plug : NGK 6801 · NGK 3830
• 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 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: B, C, D correspond to different actual diameters (52.96 to 52.98 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 85 2026
YAMAHA YZ 85 2025
YAMAHA YZ 85 2024
YAMAHA YZ 85 2023
YAMAHA YZ 85 2022
YAMAHA YZ 85 2021
YAMAHA YZ 85 2020
YAMAHA YZ 85 2019
YAMAHA YZ 85 2018
YAMAHA YZ 85 2017
YAMAHA YZ 85 2016
YAMAHA YZ 85 2015
YAMAHA YZ 85 2014
YAMAHA YZ 85 2013
YAMAHA YZ 85 2012
YAMAHA YZ 85 2011
YAMAHA YZ 85 2010
YAMAHA YZ 85 2009
YAMAHA YZ 85 2008
YAMAHA YZ 85 2007
YAMAHA YZ 85 2006
YAMAHA YZ 85 2005
YAMAHA YZ 85 2004
YAMAHA YZ 85 2003
YAMAHA YZ 85 2002