2019 KTM TPI XRC Bendix Bronze Bushing Install

In this video I install some XRC bendix bronze bushing in my 2019 KTM TPI 250.
XRC Bushing Kits: www.tokyooffroad.com/product-...
2019 KTM 250 EXC TPI with RK TEK Head
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[@matteo4096]

1:11 this is a really great idea thank you for your advice, I always enjoy watch a good mechanic at work

[@JonLloyd65]

I agree, bloody good idea!

[@alexfigueras88]

Your videos are pure gold! Thank you for sharing your knowledge with us

[@user-uh2sd3um3w]

Thank you very much You cannot get professional videos like you in Korea. Thank you all the time. Your videos are very helpful.

[@claudedenoncourt7146]

Great video , very instructive , how would you fix a humidity / condensation built up in the cover without having to remove ?

[@enduro-parts-aus]

awesome will be doing this when my bikes oem ones wear out , cheers

[@enduro-parts-aus]

should of done this sooner, one of the bushes was fully in bits and it started wearing my case out! so i just put one of the longer ones in my ignition cover to get to the none worn out part of the case

[@Redmountainsenduro]

Love your videos. keep it up!

[@milosbgd]

Graet video update! 👍🏻✊🏻Thanks

[@Strictly-laying]

I have a 2019 Ktm exc, what bush goes in what. Does the longer one sit inside the engine casing or ignition cover?

[@ptft4]

Great video! I was wondering if filling a little amount of gear oil just reaching the starter gear would work out. Then every time the bike is started a bit of oil would be sprayed around via the gears and will later reach what needs oil and likely make it last longer. I don't think the generator will mind since othher brands have oil there. Only issue could be the starter motor itself if it doesn't have a seal.

[@TokyoOffroad]

A common modification on the KTM 2-strokes up to year model 2016 was to convert the starter system to run in oil (called the wet mod). From year model 2017 the starter system was redesigned and found to be much more reliable without the wet mod and periodic maintenance. I personally have tried what your suggesting so find it difficult to comment one way, or the other, incase there is an unforeseen issue. My own bikes I've had no issues after changing to XRC bendix bushings and re-lubricating them occasionally.

[@ptft4]

@@TokyoOffroad ok interesting , so if I understand you correctly you have run with oil on a 2017 model or later and did not see any issues?

[@roberthaberman9491]

Will fork oil work as lubricant? I think I saw that on a different video?

[@bene9231]

Can anyone tell me the Number that is erased inside the Cover when long bushings where installed? I changed mine today with original ones. According to the catalog their should be a long one inside the cover. But their was a short one installed. So if the numbers inside the cover are the same I think long is the way to go. I have 55430102100R. Update: KTM Customer Service said long bushing will fit.

[@jerseyjeeper1575]

What are the symptoms of failed OEM bushings? Noise, fail to engage? Both? Seizure? The manufacturer should produce one kit with three bushings that cover both years 19/20. No one likes their bikes sitting apart waiting for parts needing to be ordered after disassembly. Great info and video as usual... thanks!

[@TokyoOffroad]

When the bushings get bad the bendix will start to fail to engage. If they get really bad they may cause the case bore to wear excessively, or crack and may cause the the gears to lock up and cause premature failure of the starter motor. It's a good idea to perform preventative maintenance to avoid any issues. To check which kit you require on the 2019, all you need to do is remove the ignition cover and look at the bushing in the cover. If its a long bushing (7.5mm) order the 2020 kit, if it's a shorter bushing (4mm) order the 2019 kit. It only takes a few minutes to check. If however you'd like to order 2 long bushings and one standard I can supply this on request. Please contact me here: www.tokyooffroad.com/contact/

[@jerseyjeeper1575]

Tokyo Offroad Yea, I got that problem! I’ll be contacting you. Thanks! (X10)..

[@jerseyjeeper1575]

Tokyo Offroad and the problem started around 40 hours

[@intosite7279]

Didn't know the tell tale signs of worn bushings, regretted it. When was changing bushings, bendix & starter, the crank case bushing was totally gone and case was worn. Bushings were loose, tried fitted it up and start, started once and failed. Opened it up and crank case totally cracked off a good 1/3 of the hole. And the brand new bendix died as well. 😭 Trying to get a whole new set of crank case and do a whole engine overhual while at it. Managed to get someone to make some brass with graphite lubricant bushings to give it a try too.

[@Grant3758]

Which bushings would go in my ktm 150xcw 2018? I have had 2 starters fail now and the bendix teeth are chewed up. Starter really struggles to turn over the engine. Only 20 hours!

[@TokyoOffroad]

Wow, that's fast! I just looked at the parts list for the 2018 KTM 150 XCW and it lists a standard length bushing for the crankcase. However, it doesn't list what length bushing is used in the ignition cover. As such the best way is to remove your ignition cover and have a look. Standard length bushings are approximately 4mm and long bushings are 7.5mm.

[@DutchFocusST]

Will this work for a 2012 300 exc aswell ? I just replaced the OEM teflon linered bushings but theyre shit, they already failed me after like 30 starts maybe

[@TokyoOffroad]

Yes, there is an XRC 4 bronze bushing kit for e-start bikes up to 2016: www.tokyooffroad.com/product/xrc-starter-bush-kit-2016-and-older/ Happy to ship worldwide at reasonable rates...

[@joeroberts1408]

What is the advantage of the XRC Bushings over OEM? Do they last longer?

[@TokyoOffroad]

Yes, the XRC bushings are made of bronze and will typically last the life of the bike. OEM bushings will require regular inspection and replacement. This video shows a 2017 KTM 300 with OEM bushes after 143H: kzbin.info/www/bejne/eamnfneMqLN_lck

[@bene9231]

I changed mine after 80hrs an ignition cover was already loose. Besides this there was no wear. I now replaced them with longer oem ones. I also lubed them with motorex spray 2000 instead of grease. Is there anything against using this instead of grease? I thought it would be a good compromise between grease and the wet mod.

[@TokyoOffroad]

XRC recommend using Motorex 2000 spray for the bendix bushings so it should be good, but I'm not able to source it in Japan so haven't tried it myself.

[@bene9231]

@@TokyoOffroad Thanks for your quick response. I will check it after 20-40hrs. Than I will see if it will also work with the oem bushings.

[@stuartbowers8111]

Hi. I did this mod, exactly as the video explains (REALLY good by the way) but I'd still really like some advice diagnosing a starting issue with my 2020 250 EXC tpi 6-Days, if you are willing? I thought installing the bronze bushes would help, but once I got everything back together the problem still persists. The bike will intermittently not crank. Sometimes when I push the start button, you hear it begin to fire - or at least that's what it sounds like, but may just be the Bendix throwing out, but then it doesn't crank the engine, you just get a whizzing/whirring sound. A few more start button presses and it will often fire with no probs, then be OK for a bit, then the problem re-occurs. It's frustrating. It has left me stranded on the start line of an enduro when the engine failed to start. It's a 2020 bike so NO kickstart as a backup either! So I want to try and get to the bottom of this if I can. I've done a lot of digging online, but alas, so far no-one seems to have any definitive advice. You are clearly the modern KTM 250 EXC tpi guru, so was hoping you might have a few ideas? (sorry for the long message!) cheers for your time, and I am very grateful of any help you can offer.

[@stuartbowers8111]

I should also state that the battery is fully charged, checked for full voltage supply, all terminals cleaned thoroughly etc etc, It's not a lack of punch from that side of things.

[@TokyoOffroad]

@@stuartbowers8111 Sorry to hear about the problem. If you're sure your battery is good, fully charged, all connections are good and it's not cold temps, then the most likely cause is a sticky bendix. Either fit a new bendix, or you could try cleaning out the one you have internally (spray in parts cleaner and blow out with air) then lube up internally with some dry lube, or light, non-tacky oil. Do not use grease, or oil which tacks up. I recently made this starter system issue debug video which you may also find of interest: kzbin.info/www/bejne/oZCZlZ94hb93bcU

[@stuartbowers8111]

@@TokyoOffroad Thanks so much for taking the time to reply :-) I figured the Bendix was the next step £££££££ and a bit disappointing as the bike has only done 26hrs!!

[@TeamStruggleBunny]

There have been a couple occasions where my start has spun over but doesn't seem engaged. Is this the beginning of starter failure. Second is replacing the bushing the fix and third will it be obvious which bushings are needed short/long or long/long? My bike is a 2019 300xcw. Thanks.

[@TokyoOffroad]

The bendix not engaging may be due to several different things. The most likely are: bushings worn, low battery voltage (cold temps will reduce the battery voltage), poor ground connection, bendix issue. Replacing the OEM bushings with bronze bushings is a good upgrade and will ensure optimal performance and help extend the bendix and starter life. Your 2019 300XCW probably has a long bushing in the crankcase and either a standard bushing, or long bushing in the ignition cover. The standard bushing length is 4mm and the long bushing is 7.5mm. If you remove the ignition cover you should be able to easily tell what length bushing is installed.

[@TeamStruggleBunny]

@@TokyoOffroad Seems to occur when the bike is working hard, like running in technical terrain and needing to be restarted several times. Occasionally it will just spin but does not seem to engage. If I release and hit the starter again ti fires up, no issues. Replacing the bushings seems like a reasonable place to start, pun intended.

[@TokyoOffroad]

@@TeamStruggleBunny - Yes, it sounds like it is a good time to replace the bendix bushings. When you have the bendix out inspect it. It may have gunked up inside a little. I do not recommend bendix disassembly, but you could try cleaning the internals out with a parts cleaner spray, then re-lube using some light weight oil. I do not recommend lubing the bendix with grease, or lube which becomes tacky.

[@stuartbowers8111]

Great video as always. Are you aware of any UK outlets for these bushes. I looked to buy them direct from your site, but with postage will cost me $50!! Thanks :-)

[@TokyoOffroad]

The postage to the UK calculated online (US$20) is for EMS service. If you don't mind slower delivery I could also send them by regular airmail for US$7. You can contact me here to discuss: www.tokyooffroad.com/contact/

[@poorwhiteboy6521]

I have a ktm 300xc 2018 can I change my Bendix without ReMoving the flywheel as well ?

[@TokyoOffroad]

Yes, it can be done. However, if you have a flywheel puller tool it is a lot easier if you remove the flywheel.

[@poorwhiteboy6521]

@@TokyoOffroad ok thank you

[@Huda88754]

Can you just put the long bushing in all models? I have a 2018 and it has enough depth for a longer one

[@TokyoOffroad]

I haven't personally measured the 2018 model case bushing bore so it is difficult to answer. I know on the 2017 model the case bushing bore is stepped, so a long bushing will not fit without modification.

[@Huda88754]

@@TokyoOffroad I just measured my 2018 300 tpi, its 10mm deep on the cover side and 9.7mm on the inner case side, I just did the repair using stock bushings and seemed like there was wasted opportunity to use a longer bush

[@TokyoOffroad]

@@Huda88754 You'd need to carefully inspect the bore and make sure it isn't stepped. If it is stepped and a long bushing is driven in it'll damage the bushing and the bendix shaft will bind on the bushing. If however the bores are straight at the depths you measured there will be no problem using long bushings.

[@Huda88754]

@@TokyoOffroad yeah there was no step either side looked smooth and straight, when the stock bushings wear out again ill order the bronze ones , wish I seen this earlier haha

[@Bimmere]

I wonder what causes my 2020xc to sometimes not turn over and I’m assuming it sounds like just the bendix is spinning... happens when temps are fairly cold, and I know a few others that have 2020’s that does this... my 2020xc has 20hrs on it and I have heard it spin freely like 7-10 times in its lifetime... my 2019 xcw tpi NEVER done that and it’s at 50hrs or so, and no matter how hot or cold it is... you know anything about this?

[@Bimmere]

Also it’s hard to record it because it sooo random when it happens

[@predragkumanov8813]

@@Bimmere did you solve this? I have same issue, on 14h. 2020 tpi 250..

[@Bimmere]

@@predragkumanov8813 it’s the temperature.. all summer long not an issue, the other day I went to start it and it did the same thing... it’s ok don’t worry about it

[@predragkumanov8813]

@@Bimmere well my bike sits in the garage.. +16c there. Still does not fire upp all the time i hit the buttom. Wonder why? Does it help to lube the freeheel and bendix part that hit it?

[@Bimmere]

@@predragkumanov8813 I am not sure, It’s the battery, it’s a lithium battery and lithium battery doesn’t like cold temps.. only thing I think you can do is get a better lithium battery with better CCA (cold cranking amps)...

[@josevelez49]

Good ! But you forgot an essential technique!! You must put those bushings on the fridge to make them go even easier!!

[@TokyoOffroad]

Jose Velez - I use that technique for bearing installation (wheel bearings). But these bushings install very easily with gentle tapping so I don’t think it is required.

[@CW-up7xv]

Why wouldn't you be able to use long bushings on any 17+ bike?

[@TokyoOffroad]

If a long bushing will fit in the bore there is no reason not to install one. But it is my understanding that the 2017 have a step in the bore which does not allow the use of long bushings. If considering installing long bushings into a bore which original had standard length bushings, inspect the bore carefully before installation. Hammering a long bushing into a stepped bore will damage the bushing and prevent bendix shaft installation

[@rocford]

@@TokyoOffroad hey do you know if the 2019 tpi bikes have the stepped bore? Or can you upgrade to the long bushing? Thanks for your help.

[@hammer49946]

It must be kind of difficult to pull out the bendix and then install because the video jumped ahead on both 🤣

[@TokyoOffroad]

Yes, you need to get it just right. It's important not to force it on install, or you can damage the case bushing. If you have a flywheel puller you can remove the flywheel which makes it very easy.

[@hammer49946]

@@TokyoOffroad I believe it's worth just taking your time like you did. I just did my 2022 xcw and it went Congrats on the subscribers. Keep the informational videos coming.

[@dazaladz]

what do these bushings actually do?

[@TokyoOffroad]

The bushing hold the starter system bendix shaft in place between the crankcase and ignition cover. The XRC bushing are machined from bronze which is an excellent bushing material due to excellent shock, wear and corrosion characteristics.

[@dazaladz]

So if the starter doesn’t engage sometimes this could be the reason why

[@TokyoOffroad]

Yes, bad bushings is one possibility. Other things to check are that the battery is fully charged and the ground connections are well secured and clean. Also note that in cold weather (particularly sub freezing), lithium battery voltage will drop and make cold starting more difficult.

[@ripnriding1]

@@TokyoOffroad interesting....I've noticed in cold weather a press of the button gets "spinning" but no engagement....figure this would be a symptom?

[@TeamStruggleBunny]

Can't get my bushing to move at all!!

[@TokyoOffroad]

Do you mean you're having trouble removing the original bushings? They typically come out pretty easily using a blind bearing puller and slide hammer.

[@TeamStruggleBunny]

@@TokyoOffroad Tried the blind bearing puller, no luck at all. Ended up drilling them out which was an experience lol. I was not keen to drill into my engine. Very slow turns with a bit that was slightly large than the inner bore did the trick. Sadly even with the replaced bushing the bike still has intermittent started issue with the starter spinning but the bendix not engaging the fly wheel. I ordered a new bendix even though mine seems fine. While I wait I will pull the original and clean it with WD40 to see if this helps.