Thread: Piston Installing 250f

Hi all again , i do have the KTM manual and have done this job a few times just wanted to know if anyone has a better way of doing it ?

Manual says put piston into barel then assemble that onto the rod , i found it easier to mount the piston then slide the barel on to the piston .
Think the main bugger of the job is the awkward little "C" clips they use , would it do any harm to use a proper circlip that you can use circlip pliers with ?? I noticed that no one sells a piston with circlips just C clips ??

Bike is a 08 exc 250 f

Thanks

did mine on my 450 that way what a f@cker that clip is to get in theirs very little room

Dya reckon it would be ok to use a circlip with hooks on so a circlip pliers could be used to make it easier ? Even if its just the one side ??

Not lookin forward to it !!

Originally Posted by G-DUB

Dya reckon it would be ok to use a circlip with hooks on so a circlip pliers could be used to make it easier ? Even if its just the one side ??

Not lookin forward to it !!

good question id be interest to what some of the others say about that as i have been wondering weather or not to do it

Been there, tried that..... wrecked a cylinder and piston in about an hour :(

You need to have the circlip with the open end downwards. Put one end into the piston, use a thin screwdriver (ground a bit thinner) in the small cutout in the piston. Prise the clip in while pressing on it with your thumb. Will go in with one smooth action. Check it is seated correctly.

i used a fairly fine bradle that fitted the groove well, like said by kev, work it in with your thumb then like putting a tyre on a rim, lever over gently with the bradle and it'll pop home in one move

always keep your thumb over it, if it pops out it will shoot in your eye!! and plug the bottom end with rags ect as i'm sure you have

was fine when i did mine, i put the piston in the barrel first as i left the engine in the bike....

it'll be fine

Originally Posted by KevInYorks

Been there, tried that..... wrecked a cylinder and piston in about an hour :(

You need to have the circlip with the open end downwards. Put one end into the piston, use a thin screwdriver (ground a bit thinner) in the small cutout in the piston. Prise the clip in while pressing on it with your thumb. Will go in with one smooth action. Check it is seated correctly.

Ok ill give that a go as ive only ever thought that the grove was there to make the clip removal easier , didnt realise it would make installing it easier too , thanks .

Sorry to hear about the failed attempt with a circlip but with the best intention im so glad it was you who tried it not me !!!!