How To Rebuild the Top End on a KTM/Husqvarna/GasGas 250 & 300 2-Stroke TPI

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  • เผยแพร่เมื่อ 23 ธ.ค. 2024

ความคิดเห็น • 112

  • @samadventures2160
    @samadventures2160 2 ปีที่แล้ว +86

    This video is aweosme I’m 14 an rebuilt my 2019 Ktm 300 exc all on my own Whatching the steps of this very detailed video 👍🏽👍🏽👌🏽

    • @mguarin912
      @mguarin912 ปีที่แล้ว +9

      Hell yeah kid. Nice work.

    • @alfa955
      @alfa955 10 หลายเดือนก่อน +3

      Holy shit my mom didnt let me ride a moped until i was 13

    • @s30ztt
      @s30ztt 8 หลายเดือนก่อน +1

      And never rode the same or started up ever again, I'm the neighbor, glad he upgraded to a real bike a 4 stroke! At least it's quiet now😂

    • @jeffcook8501
      @jeffcook8501 7 หลายเดือนก่อน +1

      When i was 8 years old my dad took a yz 125cc motor and put it in an 80cc frame and that is what I learned to ride on. Lets just say i learned respect for my bike quickly. Hit that power band, and it took off like a raped date. (as my dad would say)

  • @jimg9942
    @jimg9942 ปีที่แล้ว +3

    Great video Charles! EXTREMELY helpful to a guy who has not done a top end rebuild for 40 years!

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว

      Glad it helped!!!

  • @mattcollins3572
    @mattcollins3572 ปีที่แล้ว +2

    These are the best videos on the Internet.

  • @batipapo
    @batipapo 11 หลายเดือนก่อน +1

    Excellent video with all the detailed yet concise. Them circ clips look more like a puzzle.

  • @anthonystruik1164
    @anthonystruik1164 2 ปีที่แล้ว +7

    Excellent video Charles, thank you. I just wish that inserting the piston circlip is as easy as you make it out in the video.

    • @mschumaker1
      @mschumaker1 2 ปีที่แล้ว +7

      buy the EZ clips from Slavens. It's the only way

  • @MikeHughesShooter
    @MikeHughesShooter ปีที่แล้ว +2

    Thank you. Excellent work. Ordered kit from you because of this video.

  • @4JMcCart
    @4JMcCart ปีที่แล้ว +1

    Shouldn’t you have added coolant and let it bleed through the temp sensor before putting the tank on? (I’ve done it with the tank on also)

  • @coffeeinthemorningsun2121
    @coffeeinthemorningsun2121 2 ปีที่แล้ว +1

    Thank you for this perfect and detailed video 👍! Greatings from Germany!

  • @jview70
    @jview70 2 วันที่ผ่านมา

    Thank you very much. Very comprehensive

  • @motosz255
    @motosz255 10 หลายเดือนก่อน

    The retaining washer for the control valve in this video is triangle shaped. This is different that what is in the KTM exhaust valve blueprint which shows retainer plates instead. Where can these retainer washers be found?

  • @ChrisKAloha
    @ChrisKAloha ปีที่แล้ว +1

    Set the z before you put the cylinder on the bike. And if you don’t loosen the jam nut set screw you don’t have to reset it.

  • @corysargent5234
    @corysargent5234 8 หลายเดือนก่อน

    Question: is it wise to run the oil relay to actuate the oil pump before the first start?

  • @RICHIE_RICH89
    @RICHIE_RICH89 2 ปีที่แล้ว +2

    Start it up thats the best reward for pete sakes

  • @TwistandShout257
    @TwistandShout257 2 ปีที่แล้ว +1

    Yeeeeoooowwwww! Great stuff Charles! Keep it comin 🔧

  • @DYLLY0456
    @DYLLY0456 2 ปีที่แล้ว +2

    That’s crazy how you can get those clips in without scratching the piston at all, i did the top end on my 250 yesterday and scratched my piston on both sides🤦‍♂️ wish I had seen this video first that trick with the screwdriver would have made everything so much easier haha

  • @mastermat630
    @mastermat630 2 ปีที่แล้ว +1

    what type of grease are you using ?

  • @jakemassa8420
    @jakemassa8420 ปีที่แล้ว

    Awesome video! I’m wondering, what steps are different when performing a top end on a 150 TPI?

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว

      Your 150 will be very similar to the steps shown in this video and this will be a great guide to have on hand for your rebuild. Thanks for checking out the video!

  • @Triple9MX
    @Triple9MX ปีที่แล้ว

    You skipped the one portion of video I’m looking for, how did you loosen the nut on the cylinder on the power valve side? I can’t seem to get a wrench in there with the rod in the way

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว +1

      Shoot, we removed ours with a box end wrench. It should fit between the rod and radiator hose. Pause this video and you can see where the wrench is at. th-cam.com/video/wwLSIDFdVR4/w-d-xo.html -Charles

    • @Triple9MX
      @Triple9MX ปีที่แล้ว

      @@rmatvmc thanks for the reply, I'm wondering if there's thinner sized wrenches than what I have, I ended up having to remove the power valve mechanism to get it loosened. Thanks for the help.

  • @henning_8246
    @henning_8246 ปีที่แล้ว

    Please Help me: I cant torque the spark Plug because the cumbustion camber spins. What can I do?

  • @timslucky
    @timslucky ปีที่แล้ว

    One thing I haven't seen in any video is the orientation of the ring gaps. Is there any particular best position in the cylinder and are the two ring gaps offset 180deg from one another or what. What is common practice?

    • @robbiechiles36
      @robbiechiles36 ปีที่แล้ว

      their are pins in the ring land that orient the rings.

    • @timslucky
      @timslucky ปีที่แล้ว

      @@robbiechiles36 Thanks. Yep I found them, and she's running great.

  • @ivandelavalle
    @ivandelavalle 2 ปีที่แล้ว +2

    Best vid ever thanks so much

  • @MrSTEALTH125
    @MrSTEALTH125 ปีที่แล้ว

    what is that cleaner you are using on the power valve? I've tried oven cleaner and carb cleaner and it is still a lot of work compared to what you show in the vid

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว +1

      That's the Polaris Carbon Clean Fuel System Cleaner. You can check it out here: www.rockymountainatvmc.com/parts/polaris-carbon-clean-fuel-system-cleaner-p

  • @STHusky
    @STHusky 11 หลายเดือนก่อน

    One question can I over torque a bolt by 6-8ft-lbs more because my KDX 200 requires 18ft-lbs and my torque wrench is 25-250ft-lbs

    • @rmatvmc
      @rmatvmc  11 หลายเดือนก่อน +1

      We would not recommend it. There is a chance you can get away with it but there's also a good chance you break the bolt or cause other damage.

    • @STHusky
      @STHusky 11 หลายเดือนก่อน

      @@rmatvmc ok thanks

  • @cornellgitman78
    @cornellgitman78 2 หลายเดือนก่อน

    anyone know why the KTM manual recommends "minor engine service" (piston head replacement) after 15 hours??

  • @kordapyo612
    @kordapyo612 2 ปีที่แล้ว

    28:35 why does both piston ring ends are aligned?

    • @onthethrottle7104
      @onthethrottle7104 2 ปีที่แล้ว +1

      Look at 28:14 in the video..

    • @andrewcooksey2255
      @andrewcooksey2255 2 ปีที่แล้ว +3

      @@onthethrottle7104 not true. there is a locator pin for the rings on 2 strokes. If not, the ring could rotate and the end get caught in a port.

  • @WD469
    @WD469 2 ปีที่แล้ว +2

    Great detailed information.

  • @208enduro
    @208enduro 2 ปีที่แล้ว +1

    Phenomenal video. Thank you

  • @lifewithabe312
    @lifewithabe312 2 ปีที่แล้ว

    Would this be close to the same on a KTM 125?

  • @jacksonbuck7481
    @jacksonbuck7481 ปีที่แล้ว

    Your website sells two different OEM piston kits for the 2022 TE300i. Which kit do I need to buy? Kit #1 or Kit #2?

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว +1

      You will want to take off the exhaust control cover on the right side of your cylinder and see which number is stamped on it. Then you can order the corresponding piston. We have a short video explaining more about this here: th-cam.com/video/wwnkHIf0F7w/w-d-xo.html

  • @human1513
    @human1513 2 ปีที่แล้ว

    Great video in many ways. Thank you for making it.

  • @KhatanbaatarBuyantogtokh
    @KhatanbaatarBuyantogtokh ปีที่แล้ว

    how to repair cylinder my cylinder has a so many scratches. can you teach

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว

      We have a video showing how to inspect your cylinder and how to repair it if possible. You can check that out here: th-cam.com/video/InfPn0MtOPY/w-d-xo.html

  • @AustinM-wf5nk
    @AustinM-wf5nk ปีที่แล้ว

    What kit would you guys recommend for a 2021 husky 300 tpi with 112 hours on it?

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว +1

      We used the Vertex piston kit for this rebuild and have had good luck with them. Also, the Pro X top end gasket kit will come with all the gaskets and seals you need so you don't have to dig through the OEM parts finder and find them all individually. The first link in the video description will take you to a page where you can see all the parts and tools that are needed.

  • @brandonshreve3201
    @brandonshreve3201 2 ปีที่แล้ว

    OEM parts lists a piston 1 or 2, how can you tell which one to use?

    • @rmatvmc
      @rmatvmc  2 ปีที่แล้ว +2

      You will have to check the piston that's in your bike. It should be stamped with a 1 or 2.

  • @norton218
    @norton218 2 ปีที่แล้ว +3

    I have always been told to never use a ball hone in a 2 stroke cylinder because the balls can catch on the transfer ports and damage the cylinder. Is that not a issue anymore?

    • @keshmo12
      @keshmo12 2 ปีที่แล้ว +12

      That's 1 reason. The other reason is that the cylinders are nikasol coated and a ball hone can damage the coating. All you need to do is scotch brite the glaze off the cylinder and it's good to go. Some people say the nikasol coating is so hard that the ball hone doesn't hurt it. Ball hones are good for non -coated cylinders generally.

  • @paulinebeckett2740
    @paulinebeckett2740 2 ปีที่แล้ว +6

    Great video Charles but the only quality part on that KTM was the NGK Plug.

  • @h3aDmAsTeR
    @h3aDmAsTeR ปีที่แล้ว +1

    Thank you!

  • @Jeff-pc1zu
    @Jeff-pc1zu 8 หลายเดือนก่อน

    I would say this KTM is actually "oil injected" as opposed to fuel injection like the TBI is. If and when the oil pump goes this bike will seize up! TBI is a much better option as you still put oil in the fuel.

  • @tuckeradams9225
    @tuckeradams9225 10 หลายเดือนก่อน +5

    i wish you wouldn’t edit out the parts where you struggle. it makes it seem like it should be easy as pie when in reality it’s not that easy u just edited it out. be transparent shown it all!

  • @davidalexandru9176
    @davidalexandru9176 ปีที่แล้ว

    How to choose the corect piston size?

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว

      th-cam.com/video/60-WtFZj8AQ/w-d-xo.html Here's a link to our Piston to Cylinder Wall Clearance video.

  • @alstar300
    @alstar300 2 ปีที่แล้ว

    When deciding on a base gasket height, would it be ok to just reuse the same size as the one(s) you pulled off?

    • @rmatvmc
      @rmatvmc  2 ปีที่แล้ว +5

      Not necessarily. That might be a good starting point, but the reason you'll want to check the deck height is because the new parts can vary slightly due to manufacturing tolerances. I'd recommend checking it to avoid problems. -Charles

    • @bloomerb4162
      @bloomerb4162 2 ปีที่แล้ว +1

      My 300, the previous owner had a .025 cylinder gasket. That's way off from factory. I was worried but I knew the previous owner had a mechanic do it, so I put same size back in. It turned out ok.

    • @otmuppet
      @otmuppet 2 ปีที่แล้ว +2

      All about squish. You can fine tune your squish via base gasket.
      Most two strokes are built way too loose.
      Only fix is shaving the head

    • @nickyyoung1992
      @nickyyoung1992 ปีที่แล้ว

      The smaller base casket more compression more power.

  • @corbettenders4257
    @corbettenders4257 2 ปีที่แล้ว

    Great video, except you skipped checking the X-Distance... you show buying 3 base gaskets, how does your viewer know which one(s) to use?

  • @ericdawson3425
    @ericdawson3425 ปีที่แล้ว +1

    Thanks boys

    • @rmatvmc
      @rmatvmc  ปีที่แล้ว

      Glad it was useful!

  • @bobes919
    @bobes919 2 ปีที่แล้ว

    Where do you find a Z dimension tool from ?

    • @rmatvmc
      @rmatvmc  2 ปีที่แล้ว +1

      www.rockymountainatvmc.com/search/go?w=decking%20and%20timing%20tool%20

    • @rmatvmc
      @rmatvmc  2 ปีที่แล้ว +1

      The first link in the description of this video will take you to a page with all the parts and tools use in this video including the Tusk Deck and Timing Tool.

    • @bobes919
      @bobes919 2 ปีที่แล้ว

      @@rmatvmc thanks

  • @jimbo4203
    @jimbo4203 2 ปีที่แล้ว +5

    My dad showed me how to rebuild a 2 stroke on my 78 Yamaha it 175 . I was 14 and she was running great afterwards

  • @senor7857
    @senor7857 2 ปีที่แล้ว +13

    Spoiler alert: you are going to have nightmares with the piston circlips 😉😂

    • @woodygamer9454
      @woodygamer9454 2 ปีที่แล้ว +6

      Ez clips are your friend

    • @isaacacers3986
      @isaacacers3986 2 ปีที่แล้ว

      ive been having nightmares with the bloody piston rings cant seem to get them into the cylinder :/

    • @LukeMorphett
      @LukeMorphett 2 ปีที่แล้ว

      No kidding.

    • @LukeMorphett
      @LukeMorphett 2 ปีที่แล้ว +1

      Ezy clips sold out...

  • @enduroa.k.o
    @enduroa.k.o 2 ปีที่แล้ว

    What size piston did you go for at 80h ?

    • @rmatvmc
      @rmatvmc  2 ปีที่แล้ว +1

      We used the Vertex piston which is 66.35 mm.

  • @andreatreviso8049
    @andreatreviso8049 2 ปีที่แล้ว

    Nice job 👍

  • @alin2107nicholas
    @alin2107nicholas 2 ปีที่แล้ว

    Hey charles
    I'm wondering, if I buy the base cylinder gasket off the OEM diagram, do I get different sizes or just one gasket?

    • @CharlesTheWrench
      @CharlesTheWrench 2 ปีที่แล้ว +1

      Scroll down to #22 on the parts list or whatever number it shows for your bike, and you'll have about six options. The last two numbers in the part number should be the thickness in mm. so .20mm-.75mm. -Charles

    • @alin2107nicholas
      @alin2107nicholas 2 ปีที่แล้ว +1

      @@CharlesTheWrench thanks a lot!

    • @richardhartley7094
      @richardhartley7094 2 ปีที่แล้ว

      What size was new piston A or B👍🇬🇧

  • @sebastianlassen8674
    @sebastianlassen8674 2 ปีที่แล้ว

    Would like to see a piston change tutorial for the fe 501 2020 preferably🤣

    • @rmatvmc
      @rmatvmc  2 ปีที่แล้ว +1

      We have a whole engine rebuild series for the 450, 500 and 501. You can check out the full series here: th-cam.com/video/hkauttedsrE/w-d-xo.html
      Part 5 will show the top end assembly process, including piston replacement.

  • @freedom7047
    @freedom7047 2 ปีที่แล้ว +1

    super video

  • @EricNeilson_
    @EricNeilson_ 2 ปีที่แล้ว

    No cussing! Miraculous.

    • @tonyt1554
      @tonyt1554 2 ปีที่แล้ว

      Only because they edited part of him installing the wrist pin clips 😂

  • @senor7857
    @senor7857 2 ปีที่แล้ว +5

    Tip: do not remove the middle screw in the right power valve mechanism, then you won't have to set Z dimension again

    • @human1513
      @human1513 2 ปีที่แล้ว

      But then you cannot remove the exhaust valve control shaft behind it to clean the shaft and cylinder in that hole and replace the "o"ring.
      So why do an approx. 90% job when the engine top is completely removed and being inspected & cleaned.
      As a mechanic / technician not doing this is considered being a hack.

    • @senor7857
      @senor7857 2 ปีที่แล้ว +1

      yes, you can, at least in a 2020

    • @ChrisKAloha
      @ChrisKAloha ปีที่แล้ว +2

      The only reason you would need to set it is if you loosen the jam nut set screw. Even if you loosen the middle screw you still don’t have to set it.

    • @redball4093
      @redball4093 ปีที่แล้ว

      Excellent video

  • @cliff1551
    @cliff1551 2 ปีที่แล้ว

    You forgot the bolt on the left side arm mate

    • @mathieu6514able
      @mathieu6514able 2 ปีที่แล้ว

      At what time you saw that in the video?

  • @andreatreviso8049
    @andreatreviso8049 2 ปีที่แล้ว +1

    Subtitle Italian please

  • @csiautodetail
    @csiautodetail ปีที่แล้ว +1

    this is a lot of work every 80 hrs.

  • @jurgenjurgendebono4007
    @jurgenjurgendebono4007 2 ปีที่แล้ว

    80 hours are way to early to change the piston

    • @sakariputtonen2683
      @sakariputtonen2683 2 ปีที่แล้ว

      By the manual..

    • @michaelwcarpenter5824
      @michaelwcarpenter5824 2 ปีที่แล้ว

      @@sakariputtonen2683 Still way to early to change rings or a piston!

    • @onthethrottle7104
      @onthethrottle7104 2 ปีที่แล้ว

      @@sakariputtonen2683 Manual states 80-100 hours.

    • @MAXlMUS
      @MAXlMUS ปีที่แล้ว

      KTM just making sure they have something to eat 😁

  • @wanmuhammadfakhrullahwan8078
    @wanmuhammadfakhrullahwan8078 2 ปีที่แล้ว +1

    ,👍👍

  • @tonyt1554
    @tonyt1554 2 ปีที่แล้ว

    Torque the cylinder to spec......as he uses a combination wrench 🤣

  • @cfilmz_tv7769
    @cfilmz_tv7769 ปีที่แล้ว

    Definitely not that easy for the wrist pin clip

  • @fullyrc8555
    @fullyrc8555 2 ปีที่แล้ว

    Dam my 2014 ktm 450 is more simple than this top end rebuild! And they say 2 strokes are easier

  • @gophop
    @gophop 2 ปีที่แล้ว +2

    The whole thing about 2T top end jobs being simpler than 4T is such a meme. Would rather set cam timing than do all this crap.

    • @MAXlMUS
      @MAXlMUS ปีที่แล้ว +1

      You're not choosing between 2T/4T based on this aren't you?

  • @Ridefastorgetpassed
    @Ridefastorgetpassed 8 หลายเดือนก่อน

    Another POS Kymco cylinder. Shame on KTM.