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Ktm520sxrider

cylinder sleeve misaligned?

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1 hour ago, Ktm520sxrider said:

Word for word what you said is what the guy just told me on the phone, im gonna install it without the piston and try to see it but I'm sure that has to be the problem. he said it happens sometimes and to just file the tiny bit of extra material off. Its crazy how close the skirt and sleeve come to the crank. I dont feel comfortable with a grinder so just use a very fine metal file?

Die grinder is really the tool for the job

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clearance problem may not be totally on the sleeve , could be in combination of the aftermarket crank?

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6 hours ago, highmarker said:

clearance problem may not be totally on the sleeve , could be in combination of the aftermarket crank?

If the cranks counter weights were bigger than they are supposed to be it wouldn't have been installed in the cases. I'm guessing the company that installed the sleeve did it on friday afternoon and failed to finish shaping and clearing the bottom of the sleeve to slip into the cases and not interfere with the crankshaft.

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