2-stroke TPI Engine Issue & Easy Fix

In this video I describe a KTM and Husqvarna 2-stroke TPI engine issue and fix. Thanks to Ryan J.R. and Andy.D for the video and photos. Ryan's bike was at about 80H and Andy's bike was about 270H when they started running poorly. This will hopefully save others a lot of time and frustration.
2019 KTM 250 EXC TPI with RK TEK Head
Webshop: www.tokyooffro...
TShirts: www.storefront...
Facebook: / tokyooffroad

[@dgc21208]

This is hands down the best channel if you wanna learn something about your KTM bike and are over 25 years old, so you can comprehend the knowledge...in the sea of internet hustlers and so called experts.

[@Cupillac]

Who dislikes this video? It was perfect, helpful and short, straight to the point.

[@JonLloyd65]

My bike is brand new but now I know if I ever have a problem like this I can check the breather tube and fitting! I'm learning a lot about my 2019 250 TPI from your videos! Thanks :)

[@Bimmere]

Great to know!! Ty... approx hours on the bike when the crank pressure sensor fitting got clogged

[@TokyoOffroad]

Ryan's bike was at about 80H and Andy's bike was at 270H when it started acting strange.

[@jfritzinger]

Love your content. Thanks for sharing.

[@DirtBikingwithDonnie]

Very informative video as always. Thanks!

[@EnnTorro]

+1 happened with friends too and cleaning did the thing 👍

[@adricontrerascapdevila7069]

Hello Tokyo Offroad, I have a big problem with my Husqvarna TE300i 2020 (105h) that I can't find the solution. It's smoking so so much. I changed the crankshaft oil seal, the o-ring and the distance sleeve and the bike keeps smoking like hell. I even took the oil pump tube off the throttle body to get sure it wasn't a 2t oil problem. Where else can the gear oil get into the engine? I'm getting mad. Thanks!

[@wrenchone5003]

Thanks for sharing the info .

[@jackbauer9347]

Great video.

[@stone4858]

I change it every 35 hours because at around 40 hours it will start bogging like that one in the video and the reason I change it is because that part only costs €4 so it's not worth it cleaning I just buy 5 of them for €20 and keep them in the tool box. PS: It's an easy and simple fix just 5 minutes job and your done ;)

[@erikfrejinger2539]

What is the spare part number ?

[@stone4858]

@@erikfrejinger2539 Vacuum Connection 55430023000

[@bene9231]

@@stone4858 Is it easy to remove? Because I found only one vacuum connection in the manual and this is glued with loctite green (high)?

[@stone4858]

@@bene9231 The one I'm talking about comes with red loctite and yes it's very easy to remove

[@bene9231]

@@stone4858 with out heating it? And do you know the torque of the screw?

[@pvclassic]

Great info, thank you. Have you seen the issue of a lack of oiling? 2020 KTM 250TPI. We lost the motor after 33 hours where it showed signs of major lean condition. Lost both top and bottom. According to the trained KTM tech, it looked, to him, as if the motor had 233 hours not 33. KTM saw the pics and paid for parts, but how do we avoid this is the question. We also have a 2020 Husky 250i.

[@jfritzinger]

Any clue why some bikes get clogged and most don’t? My 2018 tpi 250 is at 155 hrs. I checked the breather tube two months ago and it seemed clean. Cleaned out the rubber hose and checked the brass fitting. No issues.

[@drdinogp]

Hello all, please solution.... im Dino from Batam Island Indonesia, i have Husqvarna TE300i 2021, my problem is currently the spark plugs often die.... when the injection test, the gasoline spray is very much, the ecu has been tested and is in normal condition, is there another possible cause? Thank You in advance.....

[@JoshuaPfenning]

Thanks for all the helpful videos. Unrelated to the topic, but what brand and model are those hand guards/wraparounds?

[@pabloguerci6757]

Excellent video! Just wondering what this sensor is really for? For example, should the ECU read though the sensor that the cylinder compression is low and lock a fault error, say wore rings or piston?

[@billybobbubbawubba9457]

A 2-stroke crankcase is coated with oil, some of that is carried through that hose. Why couldn't there be some kind of collection filter where the oil residue due goes down, and the air goes up?

[@TokyoOffroad]

This is something that could be improved on for sure. I know some people use some mesh, but that can get clogged. Wish KTM would figure out a more reliable system...

[@PR.N.R]

can you make a video on exactly the function of the crankcase pressure sensor. you mention it effects the fuel but how?

[@williamgoergen8913]

Hello, great video as always. I am looking for a direct replacement for these CCPS sensors on my 2020 that I can get from auto parts store in the states, KTM has them back ordered until 7/21. I believe the one that reads ambient air pressure is faulty as my bike seems to be running poorly again, I took to shop the first time and the mechanic swapped them and it eventually came back to life for awhile. I ordered a spare and the parts guy sent the totally wrong part. Very frustrating. Thanks

[@mxgryan]

Great info.

[@MrCartoonlife]

What oil do you use in your reservoir?? I’ve heard if you use normal 2 stroke premix it can block the oil injector

[@TokyoOffroad]

I use the recommended Motorex Crosspower 2T oil. On the TPI oill is injected into the throttle body and does not pass through the fuel injectors.

[@MrCartoonlife]

Tokyo Offroad thank you! I pick up m 2019 husky next week

[@minnionator]

Good question to ask, actually. In the marine world, premix oil is actually different than stuff for injected setups...which makes sense. Totally different delivery method, viscosity , solubility, etc.

[@RadioReprised]

Can you bore the barb out a little and make it harder to plug or is it size sensitive?

[@TokyoOffroad]

The internal bore of the brass engine fitting is 2.5mm. The external diameter where the hose fits is 4mm. If you bore it out it'll make it thinner and possibly prone to snapping. As such I would not recommend modifying it, but instead clean it out regularly (every 40H or so)...

[@ryanjordanramos]

Around 80 hours. For my 2018 tpi when that happened

[@rjg3876]

good to know

[@SWFlowseeker]

Ty for your help!

[@a.kq8984]

Man i have ktm 300 tpi and the engine dies in the trip every day I took it to the dealer and they say there’s no problem with the bike but the problem still happens every day and I don’t know what to do can anyone help?

[@TokyoOffroad]

Please describe the issue more. Is the engine stopping while idling, or cutting out while you are riding and have the throttle open?

[@a.kq8984]

@@TokyoOffroad the engine dies while im riding when i released the throttle and pulled the clutch at same time .I changed the spark plug but still ,my bike is 2020 300 tpi has 55 hours

[@TokyoOffroad]

@@a.kq8984 Have you tried increasing the idle speed? I recommend doing the idle screw mod if you haven't already done so: kzbin.info/www/bejne/in3dmpaDrdh1jdU

[@a.kq8984]

@@TokyoOffroad actually i increased the idle little bit but still this happens

[@TokyoOffroad]

@@a.kq8984 Does it idle normally when in neutral? The problem only occurs when the bike is in gear with the clutch pulled in it may be that you have excessive clutch drag. If you start the bike in gear with the clutch pulled in does it want to move forward?

[@user-ni7wq6mx6y]

Hello from Russia. I’ve been watching your videos for a long time. Changed the piston on it and not only). I sold my husky 2017, I choose a new motorcycle. How is TPI? In the first versions, as I understood it, there were a lot of problems. Should I take the KTM 2020 tpi or look towards competitors with a carburetor? And if it's worth buying, then what needs to be fixed right away? Interested in your opinion. Thanks.

[@TokyoOffroad]

I enjoy the power response and feeling of my Keihin 38 PWK + STIC and RK Tek head equipped 2017 250EXC. My 2019 250TPI feels quite different. The power stock was less than impressive and improved a lot when I fitted an RK Tek head. It produces very tractable power, but for me the carb model is more fun to ride, especially in higher traction conditions. But I enjoy riding both and rode the TPI last weekend and the carb model today. I think the comparison of 300 models is similar as I have friends who have both.

[@ah-zw4ld]

I have a te250i 2018. At steady throttle it has the same problem as your video describe. Even more, it wont rev. When intry to give it a little gas, the power is gine, The rev goes down and the bike stall. how should insay it, “bog”. Do you have the same problem? I already did what your video explain. But the problem still there. Please helop 🙏🙏

[@ShiftGearsMoto]

What did you use to get that fitting off? 8 mm deep socket?

[@nbitt1319]

Great video thank you

[@vegasromaniac]

those are the hands of a working man :D thanks for making this video, how big is your "Mousse"

[@dandoesathing2146]

I have the same symptom with the up and down revving when I'm not touching the throttle, but this only occurs if I'm using the warm up screw on the throttle body, it runs well otherwise except when I get really high in the Rev range like on a long flat out section, it starts sputtering like it's starving for fuel. Could my case also be the ccp sensor? Everyone else seems to have trouble in the lower Rev range. My pipe and brass nipple are clear, so I'm thinking of replacing the sensor but I hope it's not in vein. I love watching your videos thank you

[@jaredlambe214]

Did replacing the CCP fix your problem? I have the same symptoms on my 20 te300 as your described. Pipe and brass nipple are also clear on mine. Hoping that changing the CCP will fix it.

[@wildone2163]

so the question is why sometimes even on new bikes this gets clogged? BTW I really curious what your top end rebuild will reveal about piston and cylinder ...

[@dazaladz]

Wild One mine was nearly perfect at 80hrs. Still had cross hatch pattern on piston and good even light covering of carbon on the top

[@gsmad9738]

Hi, I’ve just picked up a 19 300 TPI in England and wondered if you could give me your thoughts on this? The speedo, odo and machine hours do not work or increase. The clocks do light up and the time and lap timer work fine. Thanks.

[@TokyoOffroad]

GS Mad - The most likely cause is the front wheel sensor. Check that there is a magnet installed in the front brake disk. Then check the sensor is installed and that the sensor cable is good and I damaged. If the cable is damaged either repair, or buy a new one.

[@gsmad9738]

Tokyo Offroad Hi, thanks for the answer and i have now fixed. FYI, because the hours wasn’t working I think I was looking for a more complex problem. I thought the hours would be more securely recorded but they are not. The magnet is needed not only for the speed, but also the hours - I did think the hours increased just on idle, but now know that is not the case. I also have a husky and the magnet on that stands out on a lug on the disc, but on my new bike, it is much more discreet and not obvious at first sight. Anyway, a new magnet and sorted. I wonder how long the magnet has been missing on my new to me 13 hour 19 model????? Cheers.

[@777-o1u]

I have major issues on my 2021 250exc. I can get it fired 2-3 times that it shuts off completely. Was running perfectly before. Seems like not sparking, but the spark plug seems to work perfectly, fuel pump is checked as well. Any ideas? Could it be the sensor?

[@TokyoOffroad]

Sorry to hear about the problem. Make sure the inline fuel line connector is plugged together fully (it should click) and check that the inline filter inside the connector is not clogged. Is the battery fully charged and voltage OK? Have you tried replacing the crankcase pressure sensor? If you don't have a spare (it's a good idea to always stock a spare sensor) you could try swapping the atmospheric and CCPS as they are the same part number.

[@777-o1u]

@@TokyoOffroad fuel line connector is plugged together fully, I'll check on the filter today, hence I think I didn't even see one, maybe the injectors are clogged too? I removed the crankcase pressure sensor, cleaned it and reassembled, hope it isn't broken. What do you mean with swapping the sensors? Thanks for your help, highly appreciated

[@TokyoOffroad]

@@777-o1u In the oil pump plastic tray there are two pressure sensors: the one with the hose connection to the crankcase is the CCPS, the other one (with no hose) measures atmospheric pressure. The two sensors are the same part number and can be swapped. The atmospheric sensor rarely goes bad.

[@777-o1u]

@@TokyoOffroad gotcha! Thanks so much, I‘ll be back with the result

[@777-o1u]

@@TokyoOffroad so the fix was a new spark plug, got a new one installed and bike goes perfectly

[@ryt2331]

What would stop the bike from revving any ideas it starts but wont rev

[@TokyoOffroad]

Have you checked for the issue (blocked crankcase pressure sensor tube/fitting) described in the video? This will stop the bike from revving out....

[@jcpaclax19]

hey have u done the throttle cable elimination on your bike to make throttle easier?

[@TokyoOffroad]

No, I haven’t. I don’t find the throttle pull heavy so have left it stock.

[@adamdoyley7017]

What was your eason to putting the diifrent read block on?

[@TokyoOffroad]

I’m not a fan of the stock reed cage. I think the VForce4 is much higher quality and more reliable with less chance of reeds breaking prematurely.

[@takistakaros9160]

I want a 300 tpi motard

[@joshwatson4654]

Hi there, I’m trying to diagnose the exact problem with my 2021 tpi, it seems to be holding revs after accelerating (half/full throttle) then rolling off the revs maintain for a little time, pulling in the clutch increases them but still disconnects the drive. Could this be the same sensor issue? Thanks Josh

[@TokyoOffroad]

No, it doesn't sound like the same issue. When the bike is in neutral and you rev the engine how does it respond?

[@joshwatson4654]

@@TokyoOffroad thanks for replying so fast, really appreciate it! I’ve just warmed it up after work and tried it in neutral and also a quick ride down the Lane and back but as is typical it didn’t seem to do it at all. I’m riding Sunday properly so will try it in neutral then. On an evening ride yesterday, when flat out trying to get up a climb and didn’t make it, it held the same revs as being wide open for a few seconds as I gestured to a mate before it started winding down

[@scottf7834]

@@joshwatson4654 did you work out what was happening with your hanging idle issue? I have the exact same problem with my Husky 250i?

[@joshwatson4654]

@@scottf7834 Hi Scott sorry for the late reply, only just seen this now, I did. So my issue was what they call a hanging idle and it was caused by the air by pass screw not being set right in relation to the idle adjustment screw I had to fit.

[@74Scoota]

@@joshwatson4654 Cheers Josh, we have ours sorted also. I completed the air bypass mod and have the screw all the way in. I also had issues with it not starting easily when cold. New top end rebuild (70hrs) and its like new again!

[@eyal1125]

Hey I have a problem with my 2018 tpi 250. When i ride, and go up in the rpm the rpm stayed very highly. Its sound like the throttle stuck but it’s not, he is working good. The rpm returns to normal only when i released the clutch an breaking hard. Can you help me? Pleas it’s really annoying, and take the fun out of the riding

[@TokyoOffroad]

Sorry to hear about the problem. One possibility is that it is running excessively lean and hanging idle is occurring. Possible causes include: Throttle body air screw too open (try closing it and see how the bike responds), air leak- check that the throttle body to reed valve hose clamps are secure and that the reed valve gasket is OK.

[@scottf7834]

I have the exact same issue with my 2018 Husky Te 250i, have done the idle mod and have wound the air bypass screw all the way in for great performance riding but is extremely hard to start when cold seems to be over rich and over fueling. But if i lean the air bypass screw out i get a hanging idle effect?

[@robsonenduro3316]

question is why it can happen in almost new bike...

[@TokyoOffroad]

It happened temporarily on a friend's TPI 2 weeks ago. He crashed by sliding off the trail on a wet log and the bike landed upside down on a steep slope . After that the bike wouldn't rev out, just like the bike in the video. We managed to get it back on the trail and took a rest for a few minutes. It then returned to normal performance. My guess is some oily residue got into the crankcase pressure sensor tube while it was upside down, temporarily blocking it, but then drained out. So I think if the bike goes upside down it could happen to any TPI, old, or new...

[@sfsf9954]

Thank god for tokyo offroad !!! Tpi god ! Lol

[@sciencemilitia1853]

Carb swap it

[@degerlitaslar375]

1

[@michail1963]

I plan at least 2000+hrs on my 2017 300 EXC with Lectron. TPI is a big step back performance and reliability-wise. Perhaps it is an answer to upcoming emissions standards, but Im not into the green leftist agenda, especially when authorities refuse to do anything about 20-40 yo trucks on the road literally spreading poison into the air.

[@TokyoOffroad]

Only 2000H! I’m not sure that I’ll ever sell my 2017...

[@michail1963]

Tokyo Offroad have you already done a bottom end? I have 380 hrs on mine (already 3rd piston). I am thinking doing nicasil and bottom end in 450hrs...btw I discovered my ohlins shock was rubbing and eating into my airboot wall. I had to round the edge where reservoir connects to main shock body...check it out if you havent already - can be nasty if a hole is created.