2023 KTM 300XC TBI Broke During Race | Episode #2 | Replacing KTM 2 Stroke Starter Bendix

Replacing a KTM 2 stroke starter bendix and bushings. Bike is still broken!
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[@TokyoOffroad]

Sorry to hear that the starter motor left the chat too. If the bendix fails and becomes locked up, if the starter button is pressed the starter motor windings can easily burn out unfortunately. With the battery fully charged and a new starter motor I hope to see you back riding Loretta :-)

[@highlandcycles]

Oh we will be back at it soon! Crap happens

[@WillyD1]

Mark is a great guy I’ve been in my garage having hard time I messaged him on you tube kept checking back and within an hour he answered me and I got my bike back together he also makes some pretty cool specialty tools I think he’s an engineer by trade

[@d.brayman3165]

Great tips! You can also use Wonder Bread instead of grease. Works well on more stubborn bushings and some bearings. Just an fyi.

[@norcalendurorider7458]

I always have a laugh when you do a Slavens impression

[@highlandcycles]

Hehehe

[@OtisFlint]

Same...gold!

[@bholway223]

I like the raw footage as well, it’s pretty cool watching the suspension flex, and seeing a different perspective going over the obstacles.

[@Tech42420]

Morgan, it's refreshing to see a task oriented person who gets real results! Thanks for the schlogs.. you have taught me a lot.

[@andyd5515]

XRC bendix bushings from Mark are one of the first things I do to bikes when I first get them.

[@The_Snowbike_Channel]

I’ve used a drill bit before to remove the bushing. Not ideal but get the bit started by hand and use locking grips to pull out once the bit gets a bite on the bushing.

[@braaaphawaii]

Good tip I’m gonna try that grease trick! Looks better than using the drill bit. That’s why I watch your channel. Keep um coming.

[@highlandcycles]

Thanks 👍

[@mikebarnato7632]

Kick start would be nice

[@LocalGarage]

Cool technique to get that bushing out. I learned something new today

[@watkinsunlimitedllc7208]

Hey brother! Want to start by saying I really enjoy your vids and your outlook on just about everything. I've grown up in small shops my entire career. I actually own my very own small auto repair business at the moment. Just the wife and I. A buddy of mine came up with a silly shop hack that worked super well for us when the air compressor was located in the work area. He simply made an adapter that allows you to clamp a universal auto muffler to the intake side of the pump. It cut the noise down incredibly well! You can just run a small engine air filter at the end of the muffler desired also.

[@highlandcycles]

That’s a great idea.

[@timsilva1944]

Yes Sir. My brother turned me onto the idea of connecting a length of hose to the compressor intake filter and route it away and/or outside. Cuts the noise in half.

[@GnarlyChicken]

Hey bud, not that this will help now, but I take my bendix out twice a yr and inspect, clean and reinstall. Like you, I have also used Mark's bushings and tool to replace the oem bushings. I had the starter out of my 21 TPI last winter to clean and inspect, and although it wasn't difficult, it was a tad time consuming as I took the motor out and set on my bench. Hardest challenge I had the first time was taking out the aluminum collar the helps retain the starter. Will always have a spare one of those on hand lol. Would highly recommend people inspecting their starters and bendix at least once a yr as they sit so low, and can get infected with water. Keep on keepin on w your great vids bud.

[@Duken4evr29]

Sorry about the starter motor - that sucks. Great video though, you have encouraged me to service my '18's bendix and likely change out the bushings.

[@Zombierippa]

You can thread a tap into that bushing and it will push it out also

[@highlandcycles]

👍🏻

[@fmtnic]

The starter bendix on my Beta was acting up and making grinding noises and I greased the flywheel gear and it solved the problem. That was well over 100 hours ago.

[@Thankyou123-h3m]

Love this channel

[@highlandcycles]

❤️

[@1176hambone]

Great impression!😂

[@groundhawg8394]

Great content great channel 👏. Got a new subscriber.

[@highlandcycles]

Welcome aboard! Thanks for

[@ShawnBlais]

@8:40 - The easiest way I've found to get these out is to just get a 5/16 drill bit, stick it in about 1/4", and pry across at an angle, pops right out everytime

[@gpfence]

Nice job Morgan! I am learning lots from you. Thankyou so much for sharing. ❤ The awesome Tokyo offroad bronze bushing installation video had a great tip for filing down a flat spot on the bronze bushing mounting face. (Engine side) Did you get it done? Without doing this, It would seem likely the bronze bushing would need to be unnecessarily removed for the starter motor to be replaced. I can't wait for the next episode. 🍿

[@highlandcycles]

The new motor doesn’t have that collar anymore so you don’t need to do that b

[@BERZERKERSV4]

We gotta get you to 100k subscribers.. ! Great content..

[@highlandcycles]

Thanks

[@mattklx]

Been buying parts from Rocky Mountain for several years now. Never had a single problem with in stock numbers or shipping. They have sent me some parts that weren't mine bundled in with my order, I get on chat with them, they give me a label and I send it back. They sent me a compression test kit by mistake once, I let them know, they gave me a label to send it back and a $10 gift certificate for being honest with them, pretty cool folks.

[@highlandcycles]

They are so rad

[@riders.oregon4474]

I used that same method on a car clutch pilot bearing using bread instead of grease.

[@philipsmith6152]

Great repair video man, I had the same prob with the tpi, screwed the starter motor. Tokyo OffRoad rocks !! I think he's an engineer?? brilliant mechanic. good luck with it

[@highlandcycles]

Thanks.

[@TeamStruggleBunny]

Had issues with the bendix in my 2019, also went with the xrc bronze bushings from Tokyo. He is very precise in his vids, think he's and engineer maybe? Nice tip on your old school way to push the old bushing out with grease. I did end up doing the starter on my '19 this summer, bought a $99 Cdn one off amazon. Does suck to have to pull the motor out though.

[@highlandcycles]

Yeah. Dumb design

[@LocalGarage]

I like the idea of fork oil, but I think I might use Maxima Assembly Lube instead. It's a little tackier than fork oil and has a high zinc content which I believe will help reduce wear.

[@barnescycle]

Light bread is thicker than grease and works awesome, also provides a snack once your done

[@highlandcycles]

Good to know!

[@chrisdubose7210]

Used your link to order a Mako360 and some other stuff for my 23 300xc three weeks ago, showed up in a couple of days and free shipping.

[@highlandcycles]

🤘🏻🤘🏻

[@DannyDifalco]

We just had a 23 300 XC in for the same issue. Bendix got stuck out. It fried the starter and bushings. Must have been stuck out for a while because it wore through the bushings and fell out. Got stuck behind the rotor and the rotor spun on the crank and sheered the woodruff key.

[@highlandcycles]

Oh no

[@onthethrottle7104]

DannyDlfalco, did the bike you mention with this problem have aftermarket starter on/off switches installed?

[@DannyDifalco]

@@onthethrottle7104 no it did not. Stock start / stop switch.

[@onthethrottle7104]

@@DannyDifalcoThanks so much for the quick reply! Much appreciated.

[@TokyoOffroad]

Personally I don't use any grease on the flywheel, or other gears, anywhere in the flywheel housing. My reasoning is that if grease is used it'll fling off almost immediately, most of it onto the case and cover, but some may find it's way inside the bendix, which may make the bendix action sticky and result in poor engagement with the flywheel when starting. I prefer to use some light oil which doesn't tack up. Yes the oil will still fling off the flywheel gear, but is more likely to find it's way back on to it and it doesn't matter if it gets inside the bendix. As part of maintenance I take the flywheel cover off and relube everything with oil periodically.

[@highlandcycles]

Great info

[@mikerasmussen7367]

Doesn’t XRC recommend Motorex 2000 lubricant as it’s an “adhesive Lube”? it’s tacky and won’t fling as much while lubricating. Motorex Spray 2000 Grease 100% SYN

[@highlandcycles]

@@mikerasmussen7367 maybe. That is what I used. But I have found that no matter what you do it flings off.

[@mikerasmussen7367]

@hylandcycles and @TokyoOffroad love both your videos! You both have help me so much with my bikes!

[@TokyoOffroad]

@@mikerasmussen7367 Yes, XRC does recommend Motorex 2000 spray (not the 2000 grease in a tub). It's not available in Japan so I've never tried it. But they also recommend not using a lubricant which becomes tacky.

[@richardhartley1705]

Didn’t know you could buy those bushes I had some made never mind 👍

[@P4ddyC4ke]

AT is the country abbreviation for Austria. :) I watch Tokyo Offroad as well. I named one of the trails he rides. "Stairway to Heaven"

[@michael397]

replace start motor is nightmare😅 but open the old start motor clean and replace carbon brush it's live again

[@reineherrera8897]

I second the Tokyo Offroad comment.

[@200xcBruce]

I have used paper towel and water and a punch to do a blind bushing removal. Is it possible the bushing OD are different since one was a loose fit the other would not go in? I would have tried in reverse once to see if specific to position. When you get your Beta, see if they still recommend 5 cc oil be put into the bendix cover area as a routine maintenance item. If those are oil lite bronze impregnated with the oil, they should last a long time.

[@highlandcycles]

They are supposed to be the same size. I watched Tokyo Offroads vid and he did the same as me.

[@keithroutley6858]

I had the same issues on my 20xc… I did the whole deal you did and was going to rip out my engine to do the starter and actually found it was the battery.. It had actually roasted my battery and drained it down.. I would add charge and it would go up but still wouldn’t actually fire the starter.. Swapped out with a good battery and it fired right up.. Worth a check before pulling engine..

[@highlandcycles]

Thanks man. Will try

[@ronhartle3268]

If the motor was turning the starter would it charge the battery and fry it?

[@highlandcycles]

@@ronhartle3268 maybe. Either way it’s junk and the battery might be too.

[@rwcasto]

LOL 😂you need those glasses on when say those things and some long grey hair maybe…😂😂😂

[@mpetkov2158]

My take: when you cased the jump, you hit your right-side aftermarket starter button which probably stayed engaged and in consequence burning up the starter, overheating the bendix bushings and draining the battery ...

[@highlandcycles]

Either that or I held the start button a little long on the start and it hung out then. Oh and my start button is on the left.

[@user-je2kh7px1f]

Hi Morgan, If you need to refill with coolant be keen to get your thoughts on Liquid Intelligence coolant. Thanks Dan

[@highlandcycles]

I haven’t heard of that

[@andreasbrodie4901]

Hi Morgan. I just had a similar issue to yours after watching your first video ironically. My bike didnt lock up but did a very slow crank just like you said. My 2023 XC250 has 130hours. Put a meter on my battery and showed 6.5 volts. Replaced the battery and I was good to go. I thought it was the starter as well because of how slow it cranked. I jumped the starter positive lug with my jump pack and it spun like it should. I also was curious how to remove the starter without removing the motor. I removed the two bolts holding the starter and it does not need much clearance to get by the frame. I honestly think if you remove the motor mounts and leave the swingarm bolt in you may be able to swing the motor up just enough to squeak the starter out. Thanks for your great content.

[@highlandcycles]

It won’t come out with just the mounts out. I tried.

[@ronhartle3268]

I was under the assumption the bronze bushings were oil impregnated bushings. So sad your bike broke especially during a race. Maybe there is a fix somehow like starter button only works if clutch is pulled in or in neutral. I hope you do well in Baja. I will be praying for you.

[@sidecarbod1441]

Bushes machined out of solid bronze will not and can not be oil impregnated, you are thinking of the bushes that are made out of powdered metal that is pressed together under great pressure to form the bush, these have pores in them (they are not solid), this allows them to hold a small amount of oil.

[@Danman1972]

I heard of some folks doing the same thing to remove a blind bearing with bread smashing it in there and it forces itself behind the bearing and pushes it out. What dry lube are you referring to? I missed that. Where did you put that? I have used graphite in the throttle housing as well as under the throttle tube. The dry lube film would work well there as well. PB Blaster and WD40 both make it.

[@highlandcycles]

I use the WD version

[@outfitr9703]

Bummer man. Was hoping that thing would spin right up.

[@highlandcycles]

Me too.

[@marcgucciardo1942]

Lucky there’s a back up kickstarter 😅

[@highlandcycles]

🤣😂

[@mikeburnett6222]

The history of the TPI's should have taught you about to the bushings. normal maintenance sugest you put the bronze in at 20 hours.

[@highlandcycles]

Most people around here never got 100hrs on those bikes before chucking them.

[@mikeburnett6222]

I got 109 hrs before i sold it, then the guy that has it, is riding the piss out of it. it's some wher around 140 and still hasn't needed a top end. I attribute the to Ledgen ZRX2 oil.

[@onthethrottle7104]

Morgan, will that fuel tank you have on your XC fit a 24 XCW if I remove the oil fill? It should, right?

[@highlandcycles]

I believe so

[@funkNretro]

2007 "I'll stick with a 300 2-stroke I like my bike basic...."2023 I'll stick with a 250f I like my bike basic" 😂

[@DavidMacPherson-ob8bc]

Loretta is just warming you up for your Beta experiment. Bummer about the starter and bendix. Enjoy BAJA 🙂🤘🤘🤘

[@highlandcycles]

Can't wait!

[@michaelpitcock2834]

Nice Trick..

[@richardhartley1705]

In this case I reckon you did hit the starter button like you said and stayed in👍

[@highlandcycles]

Yeah. Or the spring wore out and it came out. My guess is that it was from the start

[@taneumjct5156]

I guess this is why Iam reluctant to upgrade to newer model 300 I cant bring myself to give up my kicker.

[@highlandcycles]

I hear ya

[@taneumjct5156]

@@highlandcycles Then again my 300 is a 2013 most people dont have wives that long!! The starter I dont think ever did work, I pulled all starter parts put on sx cover.

[@highlandcycles]

@@taneumjct5156 I did that on my 12

[@ronhartle3268]

I had a 1991 300 that was 10 years old. I ran it until it blew up and then parted it out on eBay instead of investing money to fix it. I made just over half my money back.

[@motozz8258]

Saga Continues hehe , ktm things Buttery calls it . Not long enough, the been very good for a long time , lowering the bar of quality again these poorly manufactured revenue raisers . Rocky Mountain Lovvess them. Under 200 hrs and needs a starter now . No bush upgrade for over a decade of production? Scammin

[@richardhartley1705]

What a bummer Morgan

[@woodsrider117]

Bummer your bike broke. Hope it gets fixed fast. Come back for endurofest!!! Aloha!

[@highlandcycles]

It will be ready soon.

[@txkid123]

Morgan do you know if RMATV will be offering OEM TX300 parts? As of now the bike isn’t even listed in the drop down menu.

[@highlandcycles]

Yes they will.

[@txkid123]

Thank you! I’m at 38 flawless hours on my ‘23 TX300 but I know the times coming and hope to be able to get parts.

[@dragosvestemean4229]

dont bother with grease to extract the bushing, use a drill bit with the diameter of the bushing, weld a handle to the drill bit, and u have a good extractor tool

[@MrJacksmithFTW]

hi Morgan I'm also on the Ktm breaking boat. have you ever seen a bike where the rubber dampers have melted? well that's what happened to mine also fried discs in the process

[@highlandcycles]

Oh no. I haven’t seen that

[@MrJacksmithFTW]

@@highlandcycles can send pics

[@MitchOfCanada]

my money is that hugaberg starter has 10x the time of that KTM one lol.

[@highlandcycles]

I don’t know. It’s been sitting a really long time.

[@chrisnelson380exc]

I love Husabergs!!!!

[@zachfarkash6430]

That is a bummer about the starter. At least you know how to replace it. And it's not the whole motor that needs replaced.

[@highlandcycles]

For sure

[@zachfarkash6430]

@highlandcycles Loretta will be backup and running in no time. Sorry it happened to such a good guy. By the way your videos are the absolute best on KZbin buddy

[@ShawnBlais]

That's weird since the starter was spinning fine when you took out the Bendix in the last video. Bummer!

[@highlandcycles]

yeah, I know

[@rwcasto]

That is an old trick I would use to push pilot bearings out 🎉 works with bread too 😂

[@highlandcycles]

Good one!

[@sidecarbod1441]

The KTM starter system was junk on the first models that they fitted it to and it appears to have continued to be junk on the later models! I have a 2013 300 EXC, it was crap on that, it took many hours of work and modifications to get it to work well, these included the later laser welded bendix with the newer drive ratio, (you need to change the idler gear too), I fitted the later 410w starter motor, the bushes were upgraded too, I also went through several different batteries each one with more CCA than the last one. I'm now running an Ion battery that has so much CCA that if I use the starter with a stone cold engine it snaps the bendix in half! I've snapped two so in the end I built a 'box of tricks' that will only allow the starter system to work if the engine is luke warm or hotter. (I can't trust my self not to try it with a cold engine). I also run the 'wet mod' but I don't think that is a good idea on the later models because the starter motor will fill up the oil, this will wreck the carbon brushes in the motor.

[@calvinjones2745]

PRC!!!❤️❤️❤️

[@highlandcycles]

🤘🏻🤘🏻

[@Runk3lsmcdougal]

Will a skid plate off a 2023 300xc fit on a 23 350sxf?

[@Runk3lsmcdougal]

Turns out it won't. I was under the impression all the frames were the same

[@zxcvbnmnz]

Bendix won't throw out and engage if it has grease in it, I think it barely works as it is.

[@Tklatti01]

75 yrs experience! Lol. And his mic sux

[@highlandcycles]

Hehehehe

[@onthethrottle7104]

For someone that is a legend in their own mind, Slavens sure is a cranky old grouch.

[@matthewmcallister8845]

The grease trick works well on pilot bushings on cars/trucks as well. Bread can work as well I know I sounds weird but it can work.

[@highlandcycles]

I have done that actually

[@scootypuffjr.]

That's where I first used that trick. An old timer (he was about the same age as I am now, lol) taught it to me in 1989. I still see that guy about once a week and he comes to me for advice on some mechanical/electrical things now. He's 83 and still tinkers for fun.

[@rickyparrish2570]

Shots fired at Jeff Slavens, lol.

[@highlandcycles]

Hehehe

[@hoosierdaddy2468]

ATF is good lube for the Bendix

[@rposton919]

One word-kickstarter. Peace...

[@highlandcycles]

Agree

[@scotthouser9064]

I have accidentally started my 300xc in gear instead of neutral a coupe times. I am worried that It will cause damage like this. should I be concerned?

[@highlandcycles]

No. It shouldn’t cause any issue

[@camrendoucette5592]

What did you do to your thumb?

[@highlandcycles]

There is a video on that

[@jangoreo]

Grease, bread, wet paper towel all works like that.

[@davidgrunklee8407]

Chain looks a little tight for 23/24.

[@motozz8258]

the box is made in A.T what about the contents , hehe. Ktm dodgy for sure so who knows, in tank fuel filters were or are made in Turkey , they crack and fail prematurely . Sound like ktm things ?

[@highlandcycles]

They did finally fix that fuel filter situation

[@motozz8258]

@@highlandcycles Nice ! thanks for that info , Fuel Pumps on the 4t's ? Man its a classic ! i would need you to write a essay of reply to my knowledge of Premmy failures for your knowledge of fixed or not yet pre production :) . So i will not use your valuble time. Go well.

[@booger65man]

Can you imagine trying to pick up the phone and call that guy? I think I’d rather run my nails across a chalkboard!

[@highlandcycles]

Huh

[@booger65man]

I’ve been doing this for 75 years so don’t disagree with me! That guy…

[@highlandcycles]

@@booger65man oh. Yeah, hahahaha

[@rickyparrish2570]

To be fair, I have always had a good experience with Jeff. And he certainly does know his stuff.

[@NorthWestMotos]

Sad Morgan is sad. It would make sense the starter motor is junk since the teeth on that old bendix were chewed up good so that starter was hanging out for quite a while.

[@highlandcycles]

The chewed up teeth are the ones that hit the flywheel. I was hopeful

[@harleycarter3982]

If your in a spot white bread works better lol

[@Greg_383]

I hear people doing the "wet mod". Whats the deal with that?

[@highlandcycles]

I will talk about that in the next vid

[@jne232]

"I may be a vicitim of a Beta" I mean, KTM. They all break bro.

[@highlandcycles]

Hahahaha. I know. Wait for the vid about my KTM coming soon

[@jne232]

@@highlandcycles oh no!!! Wish these bikes were invincible! But wrenching can be half the fun!

[@ronhartle3268]

Are the kids giving you a hard time about the KTM bike even more now ? or are they laying off because it is so sad?

[@highlandcycles]

No, it’s ramped up! They are ruthless. And I’m not really sad. I have more bikes, I’m going to Mexico and this is KZbin gold.

[@liviosinibaldi3632]

"First year" model bikes.

[@rickvonderchek6898]

Take a drill bit and put it in bushing and wiggle it it will come right out

[@marianitosan9759]

You have a beef with Loctatite?

[@highlandcycles]

Really with a member of the family who owns it. The Henkel fam. One of them owns land yo here and is actively trying to close trails to moto.

[@outtherefaraway]

@@highlandcycles thanks for the info. I’ll never buy that brand again!

[@Hoser1mVm]

What pliers? Slow down Bru

[@highlandcycles]

Sorry. Look up Vampliers

[@claudioteixeira5917]

Dusty bike! 😡😡😡🫣🫣🫣🤘🏻🤘🏻🤘🏻🤘🏻

[@highlandcycles]

That’s what it gets for breaking b

[@MasterBlasterSr]

Lightly used vet owned 300Xc for sale hahhahahhah

[@highlandcycles]

😂🤣

[@LuckyNikitaBoba]

What size bolt was used to remove the starter bushing? You didn’t say much about it in the video. You tap it then pull it out with plier?

[@highlandcycles]

Sorry, was an 8mm bolt and yep

[@user-bv5kp4gr6h]

AT = Austria, en.wikipedia.org/wiki/ISO_3166-2:AT :)

[@highlandcycles]

That’s what I thought