KTM Engine Rebuild

Project Overview

Executed a comprehensive mechanical overhaul of a 2004 KTM 125 EXC two-stroke engine, undertaken entirely independently. Without prior specific experience, the project involved a complete teardown to component level to assess wear and structural integrity. Key operations included piston replacement, gasket renewal, and the complex remediation of stripped threads on the aluminum block caused by previous maintenance failures by old owners.

In the reassembly phase I prioritized strict adherence to OEM torque specifications and tightening sequences. This project demonstrates the practical application of mechanical principles, the ability to interpret technical service manuals, and disciplined diagnostic problem-solving to restore the motorcycle to optimal operating conditions.