5-5C
Checking cylinder for wear
Measure diameter of cylinder approx. 10 mm (0.5 in) below top of
cylinder edge. Check diameter in several corresponding places to see if
cylinder in worn oval.
Cylinder diameter 125 Piston size
up to Model 2000
54.250 - 54.262 mm . . . . . . . . . . . . . . . . . 1
54.263 - 54.275 mm . . . . . . . . . . . . . . . . . 2
Cylinder diameter 125 Piston size
Model 2001 onwards
54.000 - 54.012 mm . . . . . . . . . . . . . . . . . 1
54.013 - 54.025 mm . . . . . . . . . . . . . . . . . 2
Cylinder diameter 200 Piston size
64.000 - 64.012 mm . . . . . . . . . . . . . . . .1
64.013 - 64.025 mm . . . . . . . . . . . . . . . . .2
If the cylinder diameter is larger than 54.275 mm (125 up to 2000),
54,025 (125 2001 onwards) or 64.025 mm (200), the Nikasil cylinder
must be reconditioned or replaced.
NOTE: For reconditioning of the old cylinder all exhaust control
components must be removed.
Reconditioned cylinders are available on order from your KTM dealer.
The piston size is stamped into the bottom of the piston.
Nikasil coating of cylinder
Nikasil is the brand name for a cylinder coating process, developed by
the piston manufacturer Mahle. The name is derived from the two
materials used in this process - a nickel layer into which the particularly
hard silicon carbide is inbedded.
The main advantages of the Nikasil coating are:
● excellent heat dissipation and thus better power output
● low wear
● low weight of the cylinder.
NOTE: The worn coating can be regenerated at low cost provided that
the cylinders running surface is flawless.
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