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.

Shop Now | KTM, Husqvarna & GasGas 65 Top End Rebuild


Click Here To Subscribe To Our Channel!

Follow Rocky Mountain ATV/MC On Social Media!

[michaelmontgomery]

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

[timhagelburg]

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

[carsynbiggs]

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

[oubeta]

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

[paulharrison]

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…

[tuckswanger]

Thanks for you help this is what i need to know . I have 2 grandsons the oldest one is 8 and is just now starting to race. Can I download a service manual for this KTM65 if so where from. Thanks again and thanks for you knowledge and experience

[projectbabyjayy]

Could you list your tools used in video thanks

[willcountypowersports]

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

[jasonmassaro]

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

[Bruceiwish]

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

[jesse]

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

[ashlarsen]

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

[zb]

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?

[mikejoop]

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

[zyktwcg]

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.

[mustafanajm]

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

[SoLoCruizer]

i need to know if the 65sx complete motor on ebay is LegiT or not they only asking 520 free ship im like oh yea mountain bike fat tire build

[nastybasement]

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

[stevensharkey]

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

[justsendit]

Hi is this similar to a 2003 sx 65 thanks