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Thread: Stacking cylinder base gaskets on '97 KTM 360 EXC

  1. #1

    Default Stacking cylinder base gaskets on '97 KTM 360 EXC

    Hello,
    I have a '97 360 and last year I bought a used complete (36015 head, 3601 power valve assembly) cylinder off eBay. It was advertised as a'97 but i just pulled it out and checked the part number on it and it's a '96. The '97 has a longer connecting rod, so upon installation, i added multiple cylinder base gaskets to achieve a final squish measurement of .100". The bike fired right up, I haven't test ridden it yet but all seems ok so far.

    Is it safe to ride with multiple base gaskets, or is it unsafe?

    I've heard of people using one or two additional gaskets to adjust squish height safely, but for this rebuild I had to use several.

    Thanks for your input.

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  3. #2

    Default Re: Stacking cylinder base gaskets on '97 KTM 360 EXC

    I had two base gaskets on a 2012 200. Ran just fine. I used permatex high tack gasket sealant as recommended by Andrew Cooksey. I also torqued the cylinder down correctly. I would assume you’d be okay if it runs right.

  4. #3

    Default Re: Stacking cylinder base gaskets on '97 KTM 360 EXC

    I was considering doing the same thing. I have a '96 360 and thought my bottom end was bad - sounded like a rod knocking. So I bought a '97 bottom end to install my '96 top end onto. When I tore into it, turned out a prior owner mis adjusted the power valve flap (Z Dimension) and it was slightly contacting the piston. Bottom end was all good, so I cleaned up the cylinder and it looked good. Installed a new piston and all good now!
    When I was going to swap bottom ends, I was advised to install a 3mm spacer plate to be safe. The '96 connecting rod is 132mm and the '97 is 135mm..
    If you have it running, it may be ok but I'd keep a close eye on it.
    1990 KTM 300EXC (Delta)
    1988 KTM 250 enduro (Bravo)
    1989 KTM 350EXC (Sierra)
    1989 KTM 500MX project bike (Alpha)
    1992 Husqvarna 360 WXC (Foxtrot)
    1996 KTM 360SX (Zulu)
    1977 Bultaco Pursang 370 (Rojo)
    2002 Husqvarna 360 (Victor)
    1983 KTM 495 (Ditch Witch)
    1990 KTM 540 DXC project
    1985 KTM 250 MXC project
    1997 Suzuki RM 125 (Amigo)


    1987 KTM 250MX - Sold in '90 to buy 1990 KTM
    1990 KTM 250SX - Sold in '91 to go to college
    1990 KTM 125SX - Sold in '91 to go to college
    + many others

  5. #4

    Default Re: Stacking cylinder base gaskets on '97 KTM 360 EXC

    Thanks for your responses. I'm going to hope that things will be ok... trying to test ride the bike this weekend to see how things go. I didn't use a gasket sealant, but will next time (assuming there will be next time). In the mean time, I'm going to periodically check the torque on the cylinder base nuts to make sure things stay tight. I'll post an update once I see how the bike performs. Stay safe

  6. #5
    Team KTMTalk Member Picklito's Avatar
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    Default Re: Stacking cylinder base gaskets on '97 KTM 360 EXC

    As Bbq stated above, it's a 5mm rod difference. That's a lot of gasket! How thick did you need to go?
    Also, you can set the squish tighter on that bike and it will run cleaner at low RPM. About .045-.055" is very safe.
    2019 250 XC, 2015 500 EXC, 1993 500 MX, and too many old Husky's.

  7. #6
    Team KTMTalk Member Picklito's Avatar
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    Default Re: Stacking cylinder base gaskets on '97 KTM 360 EXC

    As Bbq stated above, it's a 5mm rod difference. That's a lot of gasket! How thick did you need to go?
    Also, you can set the squish tighter on that bike and it will run cleaner at low RPM. About .045-.055" is very safe.
    2019 250 XC, 2015 500 EXC, 1993 500 MX, and too many old Husky's.

  8. #7

    Default Re: Stacking cylinder base gaskets on '97 KTM 360 EXC

    I didn't do a precise caliper measurement, but i'm assuming the gasket thickness right now is close to 3mm (difference in rod length). I'm sure a custom fabricated spacer would be more ideal, but I don't have the resources or know of anyone who could make one for me. I'm reluctant to go tighter on the squish because where i live (Cali), i only have access to 91 octane. I think keeping the squish height where it is will allow me to run pump gas (barely).

    Thanks fo chiming in.

  9. #8
    Team KTMTalk Member Picklito's Avatar
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    Default Re: Stacking cylinder base gaskets on '97 KTM 360 EXC

    Oh ya, 3mm rod difference not 5. Apparently I can't do math. I noticed you were in Kalifornia like me. That 91 is awful stuff for sure. That's why I recommended that range. With better gas you can go tighter, but here in Kali it's not worth it. Much easier to run the pump swill.
    2019 250 XC, 2015 500 EXC, 1993 500 MX, and too many old Husky's.

  10. #9
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    Default Re: Stacking cylinder base gaskets on '97 KTM 360 EXC

    .100" squish clearance is alot. if your not worried about performance and it runs ok then you might be fine. spacer plates are easy to make. order a small piece of .080 thick 6061 then trace agasket on there and cut it out. put a .018 or .020 gasket on both sides of it

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