KTM TBI TOP END REBUILD 2023 2024 XC XCW EXC SX
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- Опубликовано: 16 июл 2024
- Got around to doing the top end rebuild on my 2023 KTM 300 XC TBI. This rebuild applies to all other TBI KTM brand bikes from 2023 and 2024 and onward, including the new XCW/EXC from KTM and the Husqvarna TE, TX and Gas Gas EC EX equivalents.
00:00 Intro/What I’m using
00:36 Battery info
01:03 tank removal/cleaning
01:37 Drain coolant
01:59 Plug/Hose removal
03:05 Electronic PV removal
04:08 Flange Guard removal
04:20 Head removal
04:30 Head inspection
04:40 Engine hanger removal
04:54 Cylinder removal
05:53 Cylinder inspection
06:21 Piston removal
06:41 Piston inspection
06:56 CCPS inspection/removal
07:34 Power valve inspection
08:09 Head cleaning
08:44 Setting Z dimension
09:43 Gasket removal
10:02 Power valve assembly
11:00 Ring end gap
12:06 Gasket install
13:02 Piston install
16:20 Cylinder install
17:34 X dimension setting
18:11 Head install
19:30 CCPS install
20:02 Hose install
20:28 Engine hanger install
20:40 Electronic PV install
20:58 Coolant fill/bleed
21:56 Power valve reset
23:13 TPS recalibration
24:38 Fire it up! Conclusion 
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Excellent video with clear instructions!!
Awesome work! Thank you!!
Great video mate. Thanks.
Great work and great video, thank you for posting.
Great video! Thanks for taking the time.
Well done! Great video!
Great video, thank you. Saving for the future.
Hey I really appreciate this! I am certain to follow it once my bike needs a new top end.
Very good video! Thank you!
Thanks heaps or taking the time to share your knowledge.
My pleasure!
Just bought my son a 2024 150xcw. Great video. I just subscribed
Thanks so much for this awesome video, just what I needed. I'm into 30+ hours on my 2023 300 XC will pick up a top end kit as soon as they are available since this stuff is inevitably backordered if you wait until it's time to do it. Cheers!
Happy to help! Enjoy the sweet bike👍
Great video!
Don't make fun of Tokyo off road! He has a 5 HOUR video on how to clean your dirt bike. Just kidding! Much respect to Tokyo offroad. His videos are top notch . Loaded with accurate info yet straightforward and direct without useless babbling.
Wow I'm not sure how I missed this video but the head on your 24 KTM-300xc was nearly spotless! I'm still on my old 2011 300xc keihin carbed bike and it still runs decent due to top end jobs and keeping the transmission oil changed every 2 to 3 rides and I'm actually due for another top end job now. Then I'll be looking to get a much needed new Katoom 300 xc as they're the greatest 50+ year old riders bike period. Husqvarna TX-300's are pretty awesome as well.
Well.done!!!
Nice professional rebuild!
I wish they still had Ktm manuals book when you purchased the bike I liked it better!
Indeed.
Great video and lots of good detail. I have a 2021 TE250i (TPI) and this video should help when I get set to do top end. Not sure if every step is the same for mine, but it might be close. Tokyo Offroad aint got nothing on you! 😀
All the important stuff he showed is exact same, so yes you could use this video...and yes on TPI you need to remove the exhaust cylinder clamp guard or the cylinder will get stuck hitting the frame as you remove it.
Nice job, Great video.
Thanks for the video! I think we had the same thought process. 23 250 XC here that just hit 81-hours. I decided to do the top end early as I'd rather be safe than sorry. No signs it needed it but I was curious and I am racing the bike in hare scrambles. Cylinder looks great with two very slight wear marks but can't feel them with my nail. My power valve on the pipe side was absolutely filthy though. Yours looked spotless in comparison. 60:1 Motorex for the life of the bike.
Interesting, also 60:1 motorex too. I’m kind of a lugger harder enduro rider too.
No hard enduro here. I tend to ride a gear higher too. I'm between lugging and mid range 90% of the time. Starts and straights obviously not lugging.@@TechEnduro
Power valve looked real good compared to older PV systems. I was hoping to see your disassembly/ reassembly on that new system. I have almost 40 hrs on my new 2024 300 XCW. My bike seems to run a lil richer. Spark plug was way more black with slight build up/deposit on the tip. I'm curious on what mine will look like at new piston time. Nice video!
I was ready to do the PV…it scared me to disassemble it with no guidance but it looked too clean to bother this time. Thanks!
@@TechEnduro I just did mine. Had to replace cylinder. Wasn't bad once I understood how it worked. Def taught me a lot about spots to pay attention to on it..where parts can carbonize and get sticky. Take pics of both sides w cover off before you start.
Oustanding video! If you’re an amateur I’d hate to say where I fall in the pecking order. Be something like “Baby On Board” sign on a soccer moms car.
Lol. Thanks!
Maybe I didn't catch it earlier, how many hours?
Ciao! Bellissimo video complimenti!! Ho provato il power valve reset ed ha funzionato, invece nel caso del tps ricalibrarono la manovra non ha dato risultati. Ho un 250 del 2023. Cosa potrebbe essere?
Buy a crows foot wrench for that head stud bolt
Great video, im looking at picking up my first dirtbike. I wanted to ask, how do you know when you need to do your top end? do you just go by the maintenance hours or do you feel it? Thank you in advance. Just subscribed!
A few factors. The type of bike and the kind of riding you do. For this bike the manual says shorter intervals but manufacturers are extremely conservative and the hours they state are if you’re running the bike hard at pro at race level. So if you’re just putting around you can go at least 150h on these bike, if you hard on it and a pro much less to be safe 50-80 I’d say.
Lots of different opinions on this too, don’t just take it from me, do some research…especially if you have a different modle.
question where you got the manual that shows you the cilinder meditions ? and my cilinder is showing 68mm on a tx300 tbi 2023
I noticed your comments vs. TPI cylinders like, "this is better looking than the TPI I've removed..." How many hours on those TPI cylinders? Who owned them? How were these bikes cared for? Reason I ask, I rebuild many TPI's and it's amazing how perfect they look even at 200 plus hours on a top end. The only time I see scratches or seize marks are guys that don't know how to warm TPI bikes up and, guys that use crap oil in the injector system and yes...the guys (they are still out there) that don't know how to oil an air filter. Anyway, your bike looks to have very little hours, light hours at that, and I take it you're a trail rider? So yeah, it better look that good. Excellent video, you did a very nice job and your edits are spot on, very easy and to the point. Great show. Cheers
Thanks! They were just my bikes. Same kinda riding. The TPI bikes cylinders looked good too, nothing really bad, just a some small lines that I couldn’t feel with my fingernail, and more blow by. This TBI cylinder just looked even better…so I was excited👍
Did you use A or B piston? Great video , thanks I know how tough it is to record yourself doing such stressful work lol
Thanks! I used the B Piston per the recommendation from where I bought it, Slavens Racing. "We recommend the A kit for all engines that have less than 25 hours/500 miles or engines with a re-plated cylinder. We recommend the B kit for all engines that have 25+ hours or 500+ miles."
@@TechEnduro yea I read that, just was curious if you went with their recommendation. Thanks buddy, ride on!
Is it the same dongle for both the power valve and the fuel pump (or is it the oil pump?) adjustments?
@@artrivera5331 XC tbi don’t have a oil pump it’s premix. On XCW’s it’s the same dongle yes
@@TechEnduro Thank you!
Your internals do really look good. What oil and ratios are you running?
Motorex 60:1
"Not quite Tokyo offroad clean" 😂
great video. where abouts did you get that repair manual?
KTM.com you can buy it there.
Also if you want to pay less and ok with “theft”
Go here kristofsx.com
Did you look at piston skirt on old piston for any possible crack contact? I’m sure you heard of the oem piston skirt shape possibly an issue. My ‘23 300 only has about 10hr on it, it does stick in your brain when you hear/see these things online(grenaded engines). Just curious if you looked into it..
Oh, excellent video.
I did look and it was ok. I remember hearing about 300sx engines having issues, haven’t heard of any 300xc’s though
Is the new piston "B" size, slightly larger? Or did you stay the same factory size "A"?
B piston, I think they recommend that for anything over 20 hours or so.
@@TechEnduroI think you should measure piston and cylinder clearance first before putting bigger piston in.
Did I miss how many hours you had on the engine?
Opps. 83h
Why swap piston at only 83??
@@scottyparutube big trip coming up where I’ll be putting lots of hours on and won’t be able to, plus I was curious. I’d say 150 is a good time to do it for my style of riding.
Gotcha, yeah I have many buddies that say the B is tight even at 200 or more on our XCW'S, but our riding areas and style don't include alot of time at high revs. I'm selling a 2020 XCW with 92 hours and that's all anyone wants to know is if the top end has been redone... I'm like EF NO, why? You got 100 hours to go bud.....😎
@@scottyparutubemy sx 250 got 206 hours hard enduro time on it.. running a little bit hot she still loaded with compression. A piston fresh bore. Lasting really well. I like between 80 and 100h normally but starts getting expensive
Looks a little lean, no? Zero wash on the piston crown and the underside of the crown is a touch scorched. Maybe that's normal on TBI. There's a fair amount of blow-by too. How many hours did you put on that piston?
Not sure. What does wash on piston crown mean?
@@TechEnduroClear, un-carboned patches on either side of the piston crown where the mixture from the transfer ports has "washed" the crown. When rich enough, this will cool and clean the piston crown on either side. A fully black crown usually means it is running so hot that the oil burns to the piston crown. It can run hot from being lean or running high EGT caused by too high of an exhaust restriction. I have zero experience with TBI and so it would be good if others could comment. Aluminium is aluminium no matter what engine and so the piston crown shouldn't get too hot. The underside of the piston crown is a great way to see if it's too hot. It should be clean but some say a little discolouration is OK. It looks like you have charge blowing by the piston rings too suggesting they are worn or never mated to the bore properly. That's a very shiny & smooth bore, it won't hone the rings much. That's why I asked how many hours you put on the piston. Maybe this is all normal for this engine.
Run in too gently I'd say
What sealant did you go with on the case?
No sealant just new gaskets.
so was that rebuild necessary? how many hours on bike?
I’d say you could let it go longer.
It’s a tricky thing to predict, better to take it apart and see it in good shape. This was 80h. I go longer next time.
If you can get cheap ATF I’ve used it for MANY hours in the transmission 👍🏻 Little “tech tip”
I’m curious, where is the oil injection reservoir located on this bike? Is it a tbi or tpi? I thought all tbi’s and tpi’s has the reservoir right above the fuel tank on the frame but I don’t see that on yours…
XC TBI bikes are premix, no oil injection. XCW bikes have the tanks and an oil pump.
Where did you get the instruction settings pages for the power valve and TPS reset?
Can’t remember some forum, most likely KTMTALK.com
@@TechEnduro yeah I've never seen those pages listed anywhere.
The piston in these bikes are domed. I don't think putting a straight edge across TDC would lay flat. Looking at the measuring tools out there, they show a curvature in them that takes that into consideration. So, I'm confused.
You must be looking at a tool that does multiple models, some are domed but not the 300 XC, you had me thinking I screwed it up so I check my old piston in the garage and it’s flat👍
I think the 250 pistons are domed, but not the 300’s
How many hours on your 300 now? My 2023 with 25hr has started cutting out, like you hit the kill switch. Doesn’t die, just no go when twist the throttle. It’s very random, and dangerous on jumps. Been trying to research what it could be. Have you had any kind of issue like this? Random bogg/cutting out?
Almost sounds like you have a short. Or the crank case pressure sensor.
I don’t have the 23 300 XC anymore, I now have a 24 XCW
@@TechEnduro didnt you have a lot of hours on it, regardless you obviously didn’t experience the issue(good). I guess a handful of tbi’s get it, 125, 150,250,and 300. I’ve done a multitude of stuff including checking wire harness, setting tps, changing ccps, changing fuel pump filter…it’s a random thing. Doing mx it kinda makes you hesitant hitting jumps. As much as i hate it, i am going to have dealer hook up and see, but they dont throw codes. Honestly, and it makes most sense, it seems like the tip over sensor is malfunctioning.
Did you put silicone on the base gasket? Some people day it's necessary some say it's not..
I didn’t
Did you check the power valve height setting I can't find any info on if it's still 48.5mm like the tpi?
How many hours sere on it when you did that work?
Only 80ish. Knowing how it looks now, I would’ve gone much longer to do the piston. curiosity got the best of me so I did it earlier. I would think 150 hours would be fine for the type of ride. I’m doing.
How many hours were on this bike when you did the top end?
80
do you have the part # on the dongle i guess i never got it from the dealer
I don’t know it off hand, but my bike didn’t come with it either. But it should’ve so I went to my dealer and they ordered it for free. Also, check underneath your seat towards the back there’s a small clip area where it is stored, maybe it’s sitting right there.
How do you get the repair manual?
You can buy it from KTM’s website.
What was the torque spec on the power valve. You said it’s the most Critical torque spec but didn’t mention what the torque spec was
Oh, was being sarcastic…not an import torque at all. If you really want to I believe it’s 8 or 10 newton metres
Just curious if you deglazed your cylinder?
No I didn’t
Does that red dongle come with the bike when you buy it from the dealership?
Yes.
In what proportion do you mix gasoline and oil?
60:1 Motorex
@@TechEnduro thanks
Bikes been out like a month how you gotta rebuild it already 😂
It’s a 23, I got it October 22.
Any chance of a link to get the pdf or getting the repair manual pdf emailed? I can't find one
I have the 24 exc manual pdf if you want it?
Mine is watermarked with my name all over it as I bought it from KTM, so I don’t want to share it. You can buy one officially from KTM.com/manuals or a from kristofsx.com That site is $10, obviously not officially allowed but I know many people that have bought from him with success.
B piston at 80 hr 😮
Is that unusual? I though b piston was recommended after 30 hours or something?
@@TechEnduro No. B piston recommended after 200-250 hours. Take off you pipe and check piston. Almost impossible fits B piston at 80 hr without replate the cylinder. But you measured with gauge. 🤔
80 hr piston change for racers. 200 - 250 hr is good for enduro and low rpm riders
Odd. I’ve never had an issue going with a b piston between 80-150h changes. I was going by the recommendation of Slavens Racing where I bought the kit.
“We recommend the B kit for all engines that have 25+ hours or 500+ miles. Using the B piston will bring your cylinder bore to piston tolerances back to specification.”
Also the ring gap was good, and it seems to run will now too
@@TechEnduro I think Slaven's says B piston after 20 hours. That's why he's out/been out. No one will ever need an A piston.
I can’t find a wristpin bearing and the kit I’m looking at doesn’t come with one
That’s too bad, when I bought the full kit from Slavin Racing it had it
Using old riding gloves? That’ll work.
Where did you find the repair manual?
You can buy it from KTM.com. The owner manual is free but the repair manual costs.
Also Kristoffsx I have bought, err donated for service manuals for 3 different bikes from him.
Hi
Where to find a service manual for this ktm?
KTM.com. They cost though. $50 I think it was.
What oil ratio have you ran?
60:1 Motorex
@@TechEnduro thanks for your input. Ive put ran 50:1 and im curious if thats to lean
It's brand new 🤷🏼♂️ why did it need a piston ?
Yup it’s earlier then I normally do it. Going away on a trip where I’ll be putting hours on it and I have the time to do it now, was also curious👍
83 hours? I’ve had a 2002 300 exc go 300 on the original top end. 50:1 🙆🏻♂️
Yup, I wanted to do it early out of curiosity and that I had the time to do it now. Probably could have gone a lot longer👍
is this also the kymco cylinder ?
No, Elko. You can see “Elko” cast to the side on the cylinder in the video in a few spots.
that is a really good thing !@@TechEnduro
How many hours was this piston used for?
83 I think it was s
@@TechEndurohow many hours would you recommend to do a top end? 150?
@@bradleymuha4861 yeah 150 would be good for the type of riding I do.
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why mx gloves ? Use gloves that stands break cleaner and oil.
Basically some old glove I have that I didn’t like when riding, just to avoid smashing my hand…something I do often! When there’s lots of harsh chemicals I use rubber gloves👍
Yeah, I’ll be sticking with a carb model 👍🏻nice ride though
Did you really not clean the bike before doing the top end ?🫣