2017 KTM 250 EXC Engine Top End Rebuild

This video shows how to do an engine top end rebuild on a 2017 KTM 250 EXC. My bike had done 145H when I rebuilt it and replaced the piston and rings.
2017 KTM 250 Piston rebuild kit: 00050000243
KTM piston pin easy clips: 54330074000
Tokyo Offroad piston pin removal tool: www.tokyooffroad.com/product/k...
2019 KTM 250 EXC TPI with RK TEK Head
2017 KTM 250 EXC with Keihin 38mm + STIC & RK TEK Head
Webshop: www.tokyooffroad.com/shop/
TShirts: www.storefrontier.com/store/t...
Facebook: / tokyooffroad

[@kevinwren6568]

just something to note, any time you rebuild the top end mention checking the ring end gap

[@TokyoOffroad]

Agreed. I was going to cover measuring ring end gap in the video. There is a section in the KTM service manual which covers the method, but unfortunately no minimum spec is stated in the manual, which makes it difficult to determine if the gap is OK, or not. I decided I'd be opening up a can of worms if I included it in the video so decided to leave it out. But it would have been better if I'd at least mentioned something. My experience with OEM rings in OEM cylinders is they do not require adjustment. But if you're fitting an aftermarket piston kit, or using a replated cylinder measuring the ring gap is very important. Your comment has prompted me to find out what ring end gap KTM recommends. I have asked a friend who works for KTM to find out. When it's clear I'll make an update video to clarify...

[@TokyoOffroad]

I'll make a video about measuring ring end gap and specs very soon. I'm sure it will spark some heated discussion... ;-)

[@TokyoOffroad]

I purchased my KTM Service Manual (DVD) form my local KTM dealer

[@Bradders-ik7bl]

Alright mate.... Over the years I've done a shit load of piston changes and never had one go bad but the ring gap I've never done... Not on purpose I just didn't know lol. Amateurs I know 😂 Is that just luck or does that just show it's not a must ?

[@MtlDeath]

@@TokyoOffroad If the bore was worn, it would certainly affect the compression test, hence you would have seen a problem with the initial test, and if you had used aftermarket parts like you mentioned during the replacement, this may have been necessary, but again your compression test after assembly is adequate assurance, you don 't have an issue.

[@BurtoniMotors]

I'm watching you rebuild the top end even though I don't have the bike. Your voice and video is mesmerizing.

[@maxl308]

Berlin Biker Geht mir auch so :)

[@molluscturtle]

Me too - I was actually looking for a video on a four stroke 😂

[@isaacacers3986]

Haha same

[@davidherringgo]

Great job on the the top end . Makes me want to try the valve specs. on my 16 SDR . I'm at about 9 k. now. 18 k. is recommended for checking tolerances .If compression test is fine , can skip the tear down?

[@Bikesatsomepoint]

I rebuilt my 2017 250sx using this, just wanted to say thanks for posting such a clear instructional video. Couldn’t find any of those easy circlips in time so had to use the normal supplied ones with the vertex kit and it was the most difficult part.

[@TokyoOffroad]

Pleased to hear that you found the video useful. You should be able to order the easy clips from your local KTM dealer, or online. The KTM part number is 54330074000.

[@mguarin912]

Can't believe he didn't start it for us. 😢

[@wranglerstar]

Thank you for making this video. I am no longer afraid of doing this job myself.

[@TokyoOffroad]

Overhauling a 2-stroke top end is certainly a lot easier than a 4-stroke. If you have the necessary tools, parts and repair manual there's no reason not to do it yourself...

[@user-bh9ji5el8j]

Wranglerstar why dont you make videos like that on your chanel to(Im a subscriber)

[@kyplummer3657]

You have a two stroke? Sweet!

[@steelheadstalker4715]

''HEY super glad to see you here, GOD bless you and your family maybe me and my kids will run into you and your son on the trail one day!

[@aarongillespie3352]

Great video!

[@jamesbramblett3346]

Excellent video. I don't even have a 2-stroke anymore yet still enjoyed watching your instructions. You are a great teacher thankyee for sharing.

[@ryanmoore6795]

Killer looking bike for 150 hours, man! staying on top of cleaning definitely pays off

[@TheRcscalebuilder]

I cant believe how clean and fresh your bike looks for 145 hours! Great video, very informative!

[@boblogIIIfan]

This video was playing on my phone while i was in the shed removing the barrell and piston on my 2018 300 for the first time. Thx for the help

[@BLDH]

Amazing video dude! Makes me wanna buy a 2stroker. Eaaazy game! ^^)

[@TokyoOffroad]

2-strokes are so much fun to ride off-road. Do it! :-)

[@cadwarrior]

Tokyo Offroad i totally agree!! 2 stroke are awesome to ride!!

[@EarthSurferUSA]

Rode them for all my riding/racing years. I will get another because I love them, and it's my way to middle finger the EPA. :)

[@EarthSurferUSA]

EPA--"Environ"Mental" Protection Agency", here in the USA. Watermelons, green on the outside, red, (commie), on the inside. They deserve the finger. :)

[@tkfore2one918]

"2smoker" and get yourself a 300. we out motor 250f all day long and we can tractor like a boss too

[@MarcosMartinMartin]

Awesome video! Straight to the point and all the information you need to get the job done. Excellent!

[@Lloydbar]

Fantastic video, not only in terms of the content, but also because of the shooting / editing. It's very rare to see videos of this quality made by people in their own workshop!

[@mudpro200]

Thanks so much for helping us out with these how to vids. Even I needed a refresher, it's been years since I have done a top end.

[@gordachten9722]

Dude, you work very clean. Thumbs up!

[@Atacama777]

Excellent tutorial, I really enjoyed viewing it, very professional and clear, thank you for sharing it.

[@madsen203]

Thank you for posting this. EXCELLENT video! I swear..the oil change on the 07 RFS KTM takes longer than a top end on the 2T. Thank you again for this detailed and clear video. Stellar!

[@ZanoticGames]

Super good full walkthrough, you make it easy to understand by walking it through slowly and you don't skip any steps at all

[@ProjectCrossEnduro]

Very Good Video 👍

[@sopl1424]

o lol, cxyli nie tylko ja ogladam filmy z naprawy moto ktorych nie posiadam XDDD

[@Riding4Ever]

The video is absolutely fantastic. I have a 2017 Husky TE300 and at 130 hours replaced the piston and rings following your video verbatim. The steps are basically identical on the KTM and Husky 2017 2 strokes from what I can see; You may want to make note of this for all the Husky riders out there. My only regret is not getting the KTM EZ clips as this would have been much easier.

[@Kostas283]

Steve Brown theyre basically the same bikes too,ktm owns husky

[@gupomper]

how thick was base gasket you used? Thanks

[@stughrol]

Hi. I have the same bike (TE 300 17). What size piston did you use?

[@michaelsteven1090]

Dude, you buy the kit for your bike..@@stughrol

[@alinfixo8846]

@@Kostas283 Now it belongs to bmw😉

[@_Hangman]

That bike is so clean for that many hours use. You see so many bikes with half even quarter the hours use that are beat to death. Nice job and video too 👍

[@TheRhodes76]

Great video, thanks for sharing! I'm more confident doing my own when I finally find one 🙌

[@NTKLife]

Hi, where do you find how much nm you can apply to each bolt?

[@TokyoOffroad]

The operators manual has a tech section at the back with all engine and chassis bolt torques listed

[@Meadie69]

Had me hooked even though at this point I have no use for this video. Great instruction.

[@JamisonMK3]

Excellent video! Gave me the confidence I needed to tackle this job myself! Thank you!

[@jakewilliamson7402]

Awesome video mate! Loved the thorough detail, great lighting and camera work 👌

[@TokyoOffroad]

Pleased to hear that you enjoyed watching the video

[@joewheelie2299]

Nice man. Very thorough!

[@AuMechanic]

I've added a few tips interspersed in comments regarding measuring con rod side deflection and notes on those piston clips. One more tip I would add it always place a rag under the piston as soon as there is enough room before you slide the barrel right of, this saves any carbon or debris above the piston top falling into the crank case and in some cases if you have a cracked ring and you wont know it having a rag there will stop a bit of ring falling down into the casing.

[@kyomondo]

知恵と勇気を与える素晴らしい動画です　感謝！

[@pcalvinski]

Am I the only person watching who is constantly amazed by your high-quality tools, tool bench, and the amazing cleanliness of your shop?

[@TokyoOffroad]

I made a series of videos about my shop and tools I use which may be of interest. This is Part 1 of Tokyo Offroad Garage Talk: kzbin.info/www/bejne/hIOvgnqchsp-oLM

[@darylj2617]

best how to video ive ever seen.

[@williamstones1773]

Nice video, well spoken and just the right amount of info. Love your work.

[@extremeenduro1560]

Excellent video, I thoroughly enjoyed watching.

[@MtlDeath]

Ya take care of ya bike, prolly couldda got another 50 hrs easily before the rebuild, which is remarkable. This video is not only an awesome learning tool if ya wanna rebuild, but also just how long ya can actually run a 2 stroke.. if ya maintain it correctly.. Great job

[@pjbuckmaster]

Another great video!

[@amaury1717]

Great explanatory video of the change of piston, I have to congratulate you friend, there are certain aspects that make your special videos such as cleaning, the good approach of the cameras, at every step, excellent tools, you see that you enjoythe mechanics, I follow him in his channel, greetings from Tenerife Canary Islands.

[@glenmack3640]

Mate that was a really well done video. Good sound, pics etc. I have gone from “hearing” you can do it yourself to seeing “yea I reckon I can too”. Thanks heaps for bothering!

[@TokyoOffroad]

Absolutely. The trickiest part is fitting the cylinder on to the piston and rings. Just take your time and don’t force anything.

[@RideTheTrack]

you are a great teacher thank you for the video

[@jeffreysisti6653]

Excellent video, well explained.

[@Chris-uh3cm]

You provide some of the best instructional videos on the web thank you

[@Bryankimsey]

YAY..... a nice close up of the X dimension without having to use the special tool AND you gave us some of the range.

[@michail1963]

Did that a week ago...also disassembled and serviced the powervalve...

[@TokyoOffroad]

Regarding overhauling the powervalve, how much carbon deposit was on yours? When I inspected mine I decide to overhaul it at the next top end overhaul (about 290H) due to minimal deposits).

[@michail1963]

Tokyo Offroad I had quite a lot but I didnt clean it - ran out of cleaner :D...just changed the orings and regreased them

[@TokyoOffroad]

Mikhail - What 2-stroke oil are you using?

[@michail1963]

Belray SI-7 1:55 to 1:60...I like Belray company and their products and I had plenty of SI7 bottles from the times I rode my Beta RR 300 with oil injection...Jeff Slavens advises Amsoil for clean burning but you cant buy those in Czechia.

[@kdcustoms1272]

@@michail1963 on my 04 yz250 the bike ran perfect really, but had a lot of engine noise. i found a worn cylinder and worn clutch.. i thought the power valve was fine but when i removed the main shaft, it came out in 2 parts instead of 1, it split right in the middle of where the middle bolt is on the main shaft. (a new shaft no bigger than a pencil was about $70, WTF???LOL)

[@lostinpa-dadenduro7555]

Great video.

[@123123boobies]

Subbed to your channel! Gonna need these videos when its time for a top end rebuild on my 250sx. Been awhile since ive had to do a 2 stroke but itll be a nice bit of money saved doing it myself

[@absolutebullcrap7273]

i must say even though i just watched this for the fun of it you made a very very good video about this man good job i think you will help a lot of people with this

[@sucapizda]

I just wish I can afford such supper nice expensive rags one day.

[@krazed0451]

If you're struggling to get the piston into the cylinder, you can retain the rings with zip ties. It's easy enough to push them off the piston and cut them free once you have enough of the piston seated ;-)

[@TokyoOffroad]

Good tip. I typically can manage OK using my fingers, but I wouldn't call it easy. A small section of plastic pipe with a slit in it and a zip tie round it would work well too I think.

[@kdcustoms1272]

@@TokyoOffroad good tip!

[@HimalayaHoon]

I use a strip of plastic strapping wrapped around piston and pinched closed.

[@beverlyboys73]

I am doing mine in a few weeks. Thank you for the info and video.

[@tonner987]

He he 1st time seeing your face @ 20:00, tnx for all these kind of videos. I don’t really trust people fixing my bike, tnx man!!!

[@TokyoOffroad]

I hope I didn't put you off the channel! LOL.

[@massimobroccoli9854]

I do 165 hour (vertex piston) but I change the power valves and the reeds too ! (TM250)

[@TokyoOffroad]

I'm changing the reeds (separate video). Due to the minimal carbon deposits I'll overhaul the power valve when I do the next top end overhaul at about 290H.

[@jackgariepy7223]

Massimo Broccoli I do pistons every 40 hours because at 50 they blow

[@michaelberry2298]

one time my freind told me to change the power band😂

[@ActivityPhoto]

You mean the BIG RUBBER BAND inside that makes it all work? LOL

[@MotoPoradniki]

Which color did you go with?

[@self-raisingflour4840]

BMSvideo I found pink give you an extra 50hp

[@isaeproductions5217]

michael berry I mean you can, just add a red or green

[@brianmorrison9066]

Your a pro at getting the piston back into the cylinder while compressing the rings. Last top end on my 250x I had to have my gf handle the cylinder and it still took 10 minutes. Perhaps you edited it, idk.

[@jaedenrosner]

fantastic tutorial man! when i go to rebuild my 300xc ill watch this video.

[@Booki89]

Great video! A good tip to know if your wrist pin clips are in correctly is to use the old piston wrist pin to drive them in. Also don't forget to oil up that cylinder as well !

[@danielmassee3789]

you actually have a 1/4 torque wrench....

[@aylha4851]

In Finland we call it "Yläkertaremppa"

[@joski9030]

I always remove the motor so can clean it up like new as with the frame , but you obviously know what your doing here and this way is much quicker nice vid 👍🏻

[@mestandard]

Excellent job!

[@charles1206]

200+ hours is more than ok on these bikes

[@jarrodjames6896]

How long can one expect to get out of the bottom end, or is it a don't fix it till it breaks thing

[@thomashavas2775]

@@jarrodjames6896 until you here crank bearings or rod has play in it

[@steve5912]

@@jarrodjames6896 Yep until it starts making noises or grinding/knocking. Same with the top end if it hasnt lost power dont rebuild it. Run it very Rich if you want a very long piston/ring lifespan.

[@iqmalizzat95]

dude. u can build school of two strokes engine! very educational video!

[@scottswastesystemsllc9798]

Great video on rebuild. Well done chap!

[@enduroworks9215]

The best one on youtube, thanks a lot

[@cadwarrior]

verry verry good video!!! at 14:29, i do the same as you, plus, im using a vacuum cleaner while scraping the gasket residue, works well, no chance of contamination into the base if the engine

[@SR3zzY]

Very help and educational video guide Tokyo Offroad 👌👍

[@aimlessimages831]

Excellent step by step!

[@andymackay7704]

Excellent... take note people, this is how videos should be done. Superlative!!

[@UnDoDGeAbLe]

What an excellent video, very very well done!!!

[@raymann4232]

Great video! I love watching rebuild videos. Subscibed!

[@TokyoOffroad]

Brandon - Thanks for the positive feedback regarding the video and subscription.

[@StuHNomadBiker]

Fantastic video, very well explained 👍

[@patgreen6902]

Great video thanks - excellent. All your stuff is top notch

[@tyroniousyrownshoolacez2347]

You helped me alot. Thanks for sharing. 👊

[@craigs1819]

Great video! Very good instruction! Thank you!

[@hectormiguelluzongiron7424]

Very good explained. Good job. Congratulations.

[@justinmoto929]

On my 2016 KTM 250sx the compression test before my rebuild was around 140 psi... definitely time for a rebuild haha

[@jessarellanes6648]

Just curious what was your compression after, I have 105 hours on my TC 250.and it still is running great.

[@jamielee2702]

Going to do mine this sunday 😁👍🏻

[@mattiasmyrman]

Love this video! Thanks!

[@IgorTurgenev-UK]

A very informative video. Thank you

[@techmarkie]

Great clear video! It will definitely help when i rebuild an older KTM 250 SX this month, i was unsure about checking and adjusting the x-dimention! I'm used to top end rebuilds of a tuned Honda CR125R, that has a metal base gasket so nothing to adjust! A comment though, I always lightly hone the cylinder and also check the ring end gap (which is usually too small and needs to be filed slightly to hit correct tolerance). We only do 20 hours on those pistons and 60 hours on the crank, its incredible you get so much out of your pistons, How many hours do you think you will get out of the crank?

[@MrJohnmccrory]

very nice vid ! very clear and helpful . great job

[@burntfaceman24]

Great video! You seem to know exactly what you area talking about. You could use crows feet for the front cylinder nuts in order to torque them properly. Crows feet are really great for tight spaces!

[@TokyoOffroad]

Pleased that you enjoyed the video. I made a separate video after this one in which I discuss some solutions for tightening the difficult to access stud nuts which may be of interest: kzbin.info/www/bejne/mH_SemuEmJygoaM

[@p.t.3726]

What a nice video. I ride 4stroke, but would love to own 2stroke as well.

[@medaloko333]

fantastic video! One question, what two products did you use to clean the stock? It was better than factory!

[@rodneykinder9441]

Very good video. Top notch work. I have a 1997 360 exc. Bought new, ran it very much. Never opened it up. Ive also a 1998 360 i recently bought. May redo it first, as its life is unknown. Both run very good, i really want a new 300 injected bike but may freshen up what i have. Probably too old for a new bike. 97 runs great after 20 plus years, and i did run it hard, got it hot etc. Probably had 20 rear tires on it. Ktms are good in my book

[@bast2957]

Thanks you a lot; it's time to replace my piston off my 250 TEi; it's a little bit different but your instructions help me so much.

[@TokyoOffroad]

How many hours had you done and how did the piston, rings and cylinder look? I have just bought a 2019 KTM 250 EXC TPI so I'm interested to know whether the top end will wear as well as my 2017 KTM 250 EXC (carburetor model)...

[@bast2957]

The bike have 76 hours; i can hear small noises during deceleration so i prefer changes it. But my bike got some problems with the injection at the start and suffered lot of tests for the diagnosis. I will changes it when i received the new piston (this week i think); if you want i can send you some pictures of the different parts when that is done. Sorry for my bad english ;)

[@TokyoOffroad]

The 2019 map for the TPI is meant to improve starting. Maybe discuss with your dealer if they can update the map...

[@bast2957]

I mean "at the start" when i just buy it; at 20/25 hours; when i accelerate quickly the bike suffocating like a bad carburetor adjustement; the customer service never found what is the problem; they just change entirely the system of injection. A real nightmare during 2/3 months!

[@jacobvogt8996]

Is that a 4 stroke or 2?

[@mikeross9910]

Excellent, very informative video!

[@beaupollard963]

great channel keep the content coming 👍🏼

[@woodworm3615]

Great video. Very good to refer to when its time

[@sergiocarlos1722]

nice and clean work . congratulations .

[@Gavin-The-Maniac]

that was a great install video

[@sam-ww1wk]

You make great videos. Keep up the nice work.

[@cobusvandermerwe6144]

@Tokyo Offroad. Awesome video. Any idea on the X dimension on the 2017 300

[@user-jw9dh6ut9x]

Mind blowing so impressive to watch

[@939sp8]

Amazing video! I wish I could have it 15 years ago when I changed cylinder and piston my honda dio! Especially the arrow at. the top of the piston! just for the record the scooters engine died a few months later xaxaxa

[@Thatcressidaguy]

did it run, great video great camer shots, great audio and more this video was awesome and entertaining even tho i ride a yz125 thanks for ur time

[@TokyoOffroad]

Thanks for the positive feedback. Yes I've started it and taken it for a test run. I'm riding it this weekend for two days which I'm looking forward to :-)

[@reignhealth]

Very nicely done, great video!

[@Micscience]

I used to put all my nuts and bolts into trays when I first started wrenching through experience I have learned to put them back in place where they belong. This way you know exactly where it goes and you don't lose them and if you forget something the nut or bolt will give you the clue. Anyways nice job and nice bike.

[@sape74racingsp]

Vers,very good channel....Thanks for all infos👌🏻😉

[@mistersubby]

Thank you very much for the video. Good tutorial as usual.

[@darrenbutler160]

Excellent, very informative . Thanks

[@EddiNice]

How do you decide what piston size to put, before you took it apart? Thanks

[@sandromarkovina2597]

Hi, I watched your video a few times, very good and detailed work done, with some great informations. But I must ask, what spray did you use for cleaning the cylinder head (the second one)?