top end rebuild advise please

[britishgas]

i am going to change the piston in my 2012 300 ,does anyone have any instructions / advice / links on how to do it thanks british

 

[Krasi]

Workshop manual helps a bunch:

https://dl.dropboxusercontent.com/u/98179648/2006 EC 200-250-300 tyokirja eng.pdf

 

[desertgasser300]

Check on you tube, some one may have a step by step on doing a 2 stroke top end. It might not be a gasgas specific but they are all pretty much the same. And take your time don't get it a rush. If you are uncertain of where pieces might fit back together take lots and lots of pictures.

Sent from my SGH-T999L using Tapatalk

 

[britishgas]

I have rebuilt lots of ktm two strokes with no problems .is the gasgas similar

 

[twowheels]

If it was running well, be sure to measure the base gasket (s) and replace with the same. If you want sharper performance pull the head but leave the jug on. Check your piston to exhaust port height (see F5 or Jakobi thread) and then decide on base gaskets. Check/set squish based on your new (or carryover) cylinder height.

PlusOnePerformance

 

[Batman Bailey]

Thinner base gasket

If it was running well, be sure to measure the base gasket (s) and replace with the same. If you want sharper performance pull the head but leave the jug on. Check your piston to exhaust port height (see F5 or Jakobi thread) and then decide on base gaskets. Check/set squish based on your new (or carryover) cylinder height.

PlusOnePerformance

I ordered new gaskets with my top end and the new base gasket is half a thick. Where will that help and hurt at?

 

[Jakobi]

Only other thing to take note of, is when disconnecting the PV on the RHS use a little heat on the nyloc nut (or just be gentle). Also check the tension while you have the bike apart, and resist the tempation to pull up and manually operate the actuator arm/plate while the bike isn't running. It can dislodge the ball bearings in the governor making more work for you.

 

[stian]

I have rebuilt lots of ktm two strokes with no problems .is the gasgas similar

Define lots? I mean, if your in the MX-game, and doing rebuilds, you know the way around a engine : - )

Just take it out. Only thing that can be a hassle is the PV.
Be carefull with clearences. Tight, but not to tight with rings,pistons.