How To Rebuild the Top End on 2009-2021 KTM, Husqvarna & GasGas 65cc Dirt Bikes

Whether it's because of excessive noise or just wanting to refresh your engine for the riding season, rebuilding your top end is a great way to get familiar with your bike and prevent more catastrophic failures in the future. Knowing how to do the job correctly will save you tons of time and money compared to taking it to a shop as well. In this video, Charles shows how to rebuild the top end on a KTM 65 SX, but this process will be very similar for Husqvarna TC 65 & GasGas MC 65 dirt bikes.
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[@michaelmontgomery3267]

I used this video to rebuild my first top end and it went great. Bike is running stronger than ever!

[@timhagelburg730]

Great vid Charles makes life so easy looking after these bikes.

[@oubeta]

Thanks for making the video. We ordered all of our parts from Rocky Mountain

[@carsynbiggs187]

Just did mine!! Thanks for the help!!!

[@rmatvmc]

Awesome! Glad the video helped!

[@oubeta]

So helpful

[@jacquesnel8384]

Really good 👍🏻

[@adonyscz1271]

Thanks super video

[@projectbabyjayy3653]

Could you list your tools used in video thanks

[@paulharrison3631]

Just sent our son’s 2020 KTM 65 into the local KTM shop for a clutch issue and they identified that it also had a broken power valve that had become so damaged that the cylinder needs replacing. They also said the cylinder and the parts for the top end rebuild are on back order until December 2021 🤷🏻‍♂️. Glad they found the issue but not thrilled that my son is potentially going to miss half the riding season…

[@raymondharold5973]

Us chrome can fix any problems with your cylinder and it will have a stronger plating w/ better oil retention.
Also the water pump impeller is plastic and comes apart it should be inspected regularly (visually or black floating particles in the radiator fluid)

[@jesse469]

Hi, could you tell me the ring end gap measurements,min-max for husky tc 65 for vertex piston.

[@ashlarsen3845]

I’m having issues with the X measurement. I have about .6mm after using the smallest gasket .2. Any idea why I have such a gap? 2016 KTM 65 using a vortex piston rebuilt kit from RM (you guys) Thanks

[@justsendit3217]

Hi is this similar to a 2003 sx 65 thanks

[@willcountypowersports6338]

It’s safe to use a ball hone on a nikasil cylinder?

[@matthewclark121]

My power valve was broken also.

[@zb7338]

My son's 2021 gas gas 85 does not have a clear timing measurement on the fly wheel etc I looked for a manual that shows it with no luck. Can anyone help?

[@stevensharkey6909]

Hi my gear box oil is turning milky after a few rides I've changed the water pump seals but its still doing it please have you or can you do a video on this issue we have a KTM SX 65 2019

[@rmatvmc]

www.rockymountainatvmc.com/parts/nihilo-concepts-reusable-inner-clutch-cover-gasket-p?v=15836 Did you replace this gasket too? Coolant flows through it. -Charles

[@lbaraby]

It's a pretty common is on these. lts probably not coolant and just water from washing/riding. Change the fluid often. Its cheap and easy maintenance!

[@Bruceiwish1234]

What’s the black brush made of that you are cleaning the cylinder with. And dimentions please.

[@rmatvmc]

Flex-Hone Cylinder Ball-Hone: www.rockymountainatvmc.com/parts/flex-hone-cylinder-ball-hone-p

[@mustafanajm965]

Thank u for the video i have question please i have this bike im going to repair the top end but what the different between oem top end and vertex top end please help thank you

[@rmatvmc]

Either one is a good option. I'd just get the new parts installed and call it good! -Charles

[@nastybasement6232]

Hi ! What diameter and grit hone do you use for the SX65 cylinder ? Thank you

[@jesse469]

42mm-45mm

[@Spacecruizer203]

i need to know if the 65sx complete motor on ebay is LegiT or not they only asking 520 free ship im like huhhhhh oh yea mountain bike fat tire build No?????

[@jasonmassaro7873]

Just purchased a used 65sx with no hour meter. What psi reading should I expect to get for good compression when testing?

[@rmatvmc]

Your psi should be around 150psi

[@jasonmassaro7873]

Thanks!

[@mikejoop9838]

How many mm must timing adjusting ktm sx 65 2006? I dont have timing tool

[@paulleet4772]

1.1mm

[@user-zy2kt6wc6g]

Is piston replacement possible without removing the cilinder head? Is there enough space between engine and frame? I know it is not the right method for piston replacement.

[@christucker282]

No

[@ZmannR2]

It’s super easy to remove it

[@jmac636]

Yes there is enough room. In a pinch I did a top end at the track and was able to remove the cylinder by removing the spark plug and coil to allow enough room.

[@NJOMBIKASOFU]

hello, i need a link on where to replacement parts

[@rmatvmc]

The first link in the video description will take you to a page with the parts and tools you need to get the job done.

[@user-rt6jy2te4c]

🔥💯🛵🏁✊

[@yeetfeet1601]

A 65 with a power valve that’s definitely weird

[@ZmannR2]

All modern racing 2 strokes have power valves