I FIXED THE KTM 300XC | TBI POWER VALVE | OVERHEATED KTM 300 | HIGHLAND CYCLES

I rebuilt the 23 300XC after I overheated it badly and it RUNS!!!!
Stay tuned for more beating and testing!
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[@dallasknoll7943]

Does the Samco hoses eliminate the thermostat? Can I get these through your website?

[@highlandcycles]

It does. I don’t have them on my site but 1sttrackmoto.com/highlandscycles has an S3 version that’s less money and the same thing.

[@chrisbracken7889]

Tuff break bud...chin up

[@wednesdar452]

KTM should sell their bikes with fans like Sherco!!

[@200xcBruce]

I would like to share a bit of knowledge with you about tapping. If you can have someone take a steel block maybe 3 inches by 3 inches and 1 inch thick, then drill clearance holes in it through 1 inch dimension side, for any taps you plan to use. Then you can hold the block on the work piece you are tapping, insert the tap through the block and your guaranteed to start the tap perpendicular to the work piece.

[@highlandcycles]

Great tip!

[@garwri92]

Tapping block

[@bryanha79]

Looks like the real cause of the problem was the clutch abuse that caused the motor to overheat and the T pice to fail.

[@highlandcycles]

Yeah. But I personally don’t have another way to get up that nasty trail.

[@chewyexc]

I feel the same most the time. We are human and make mistakes... If I was perfect I would not be working...

[@d.brayman3165]

Glad you got it running again. A couple of tricks for you--1. put grease in your tap flutes and you'll get very few stray chips. 2. WD-40 is probably the best cutting/machining oil for aluminum. For what it's worth. Great video!

[@highlandcycles]

Thanks man.

[@markaddy53]

great job as always lad glad u got it sorted next video please

[@cooptroop5]

Put cylinder studs in and nuts like a Yamaha

[@jiricabadaj8397]

Everything will be OK, thanks for the exciting video. I wish you good luck!

[@Tech42420]

Seems like a lot of issues with your 300. Watch out for that automatic turn on of the fan it'll run down your battery. None of the manufacturers design bikes to run at our altitudes. BTW, I'm a guy who loves my Rekluse😂. I absolutely love your Channel!!😊

[@highlandcycles]

Thanks. Yeah the controller is an issue. I think I will eventually wire it to my True North harness that shuts power after bike is off for a bit

[@scott645]

With the level of overheating, you likely will need to replace the right side crank seal. Keep an eye out for transmission oil burning.

[@highlandcycles]

For sure

[@alexkevan3887]

Good go know you can helicoil repair the cylinder. Hiw many hours are on this bike? Also the clutch.

[@highlandcycles]

260 on bike and about 20 on the clutch

[@Frostbyte911]

For the amount of money you spend on a ktm, I would think they would put metal impellers and gears in their bikes and stop using plastic ones……

[@highlandcycles]

Agree

[@jimzigouris]

have you limk for the lights on bench and for the rear exhaust enduro1? thank you

[@highlandcycles]

The lights are from omniwall and that link is in the description. The exhaust isn’t live yet but will be at 1sttrackmoto.com/highlandscycles

[@scottphillips445]

Don't feel bad. So you blatantly destroyed some engine parts. I am actually speechless after seeing the "game changer " get analy abused like that. You should have been on the beta

[@highlandcycles]

Except it wouldn’t have made it to the gas stop with the tank on it b

[@ShawnBlais]

Did you upgrade the stator for that fan? The stator on the new XCs is weak af, fan will kill your battery by the end of a long ride.

[@highlandcycles]

I did a while back

[@adamtherriault1250]

40K

[@valeriel1292]

The tusk fan can't be plugged into the wiring harness therefore using the ecm as a control?

[@highlandcycles]

Correct but the XC bikes don’t have that option anyway. Only the W

[@johngray722]

ktm have been doing that T peice for years and for years it fails bad idea nobody else does it and yes i blame ktm

[@husaislander4838]

I dont think a fan would have helped you any once you were out of fluids. Also a former machinist put a little grease on your tap will help to grab the filings while your tapping. Hope it all last for you!!! But you really should get a Sherco. HaHa 🤘🤘🤘🤘

[@lozadazx14]

I think the crank bearings have to be cooked too with that overheating Morgan 🙆🏼‍♂️ hope is ok 🤘🏻

[@highlandcycles]

We will find out

[@jamesg5059]

“I’ll probably get some shavings down into the cooling system but I don’t care” says the guy that is doing this work specifically because the bike overheated 😂 you kill me man. TBH I’d do the exact same thing to a 2T

[@highlandcycles]

I don’t care because they are easy to blow out

[@chriskindberg7212]

Keep the dumb comments coming! You make the man money 😂

[@BAYAREAMX]

The cylinder and piston is available for the 2024 but not for the 2023. They’re the same but there must be some very small difference between the years. Maybe the 2023 is the elko and the 24 is kymco.

[@woodysrockspyro6436]

You should find a cheap grizzly mill. They are awesome as a drill press and perfect for keeping drills and taps straight. The smallest floorstanding model would be fine.

[@scottcoplin8322]

Great video, I was stressed just watching it, cylinder cleaned up nicely via vapor blasting, looked like you ran the hone through the cylinder, thx for the details on the power valve, looks easier than earlier models. Nice job Morgan.

[@highlandcycles]

Thanks. Yeah, once you figure which side the parts go in it’s super easy

[@kweholt]

Is that a new cylinder? If not how’d you get it so clean ??

[@highlandcycles]

It’s not. Vapor blast

[@randytidwell5836]

motorex? when i had my 2021 Husqvarna te300i i was running Redline. The manual recommended Motorex. A friend i ride with was telling me i needed to try motirex cause thats what they designed the motor around being it was recommended in the manual so i did. it was summer about 95° and at the end of the day the outlet of the siliencer was totally dry, light brown and looked like a car exhaust. before i ride again i removed the motorex from the injector tank and refilled with redline that kept a little bit of drool on the silencer. i perfered keeping the ehaust slightly damp rather than complete dry. just me.

[@Dirt_Serpent]

Ktm recommends motorex because they make motorex, just like Yamaha says to use Yamalube. That’s honestly just a scam to get you to buy only into their ecosystem.

[@TokyoOffroad]

@@Dirt_Serpent I just looked up Motorex company ownership. The Motorex website states that it's an independent family owned business: "As early as 1917, the pioneer Arnold Bucher began producing the leather and floor care products REX in Bützberg near Langenthal. As motorization increased, the business activities shifted - REX became MOTOREX in 1947. MOTOREX-BUCHER GROUP AG is still an independent family business. We are proud of that. Our employees feel and live respect and appreciation."

[@human1513]

Different oils have different flash points. A lower flash point oil works best for trail riding and higher flashpoint oils are best for full throttle racing. This is in part why differtent oils will or will not produce spooge out the silencer. Low flash point oils will burn at a lower cylinder / piston temperature. So I imagine the Red Line oil has a higher flashpoint and is not being fully utilized and not fully burned in your bike. 5 I know of: 1). Liqui Moly 2T Synthetic Offroad, red label on bottle: ⚡⚡Flash point 98 °C (208.4 °F). This oil is specified per the bottle for Huskies, and is used by Beta bikes. 2). Motorex Cross Power 2T: ⚡⚡Flash point >110 °C (230 °F). Recommended for KTM. Husky & Gas Gas. I know many who use this in KTM 300cc for trail riding at 60:1 with great results as I do. 3). Motul 710 2T: ⚡⚡ Flash point 154 °C (309.2 °F). Is for premix & oil injection systems. I know many who use this in KTM 250 & 300cc and YZ250's for trail riding at 60:1 with great results. I have used it also. 4). Motul 800 2T Factory Line Off Road:: ⚡⚡ Flashpoint 252 °C (485.6 °F). *** Is for premix. 5). Red Line Two-Stroke Racing Oil: Code: 828918: ⚡⚡Flash point: 98 °C (208.4 °F ). safetydatasheets.phillips66.com/MyDocuments/DownloadSingleFile?content=6FAB87AF-FAD4-45C4-BFB4-0883F3961E04_PDF 6). Klotz R50: ⚡⚡Flash point: 204 °C (400 °F ). *** Is for premix. Red Line: www.redlineoil.com/content/files/tech/Two-Stroke%20Technical%20Info.pdf www.redlineoil.com/Content/files/tech/2_STROKE_RACE_OIL_TEST.pdf

[@zachfarkash6430]

Awesome glad to hear it run again, good work 🤘🤘

[@senor7857]

This could be the worst video of tbi power valve explanation 😂😂😂 Love it!! 🤣

[@highlandcycles]

Haha.

[@MikeRay1978]

Listen brother. I love your content. You’ve helped me over messaging before. But you listed every thing that went wrong and could have prevented this except one thing. lol you could have laid off when it started steaming and running hot and figured out a different way to get the bike out. Again not hating I love the content.

[@highlandcycles]

I thought that too but I don’t think so. It wasn’t steaming at the cap. The t hose broke so the only way to no over heat it would have been to tow it out. And that is no trail for that

[@MikeRay1978]

@@highlandcycles that makes sense. Love the content!

[@MikeRay1978]

@@highlandcycles I just watched a video of where you were. Dude. You’re a beast. I can’t even ride something that gnarly at that pace. Awesome man.

[@donaldblank8873]

You may need to file the fins down on the new impeller. Usually they come much bigger than the stock and your bike will never heat up properly to run right, especially if you remove the thermostat Filed mine down on my TPI 250 To just slightly bigger than stock and it holds between 170 and 189 throughout the hot summer in Oregon. This is hard enduro riding, I can even slip a plastic cover in front of one radiator when it is cooler to keep it up to temperature.

[@seamarsh3756]

what about plastic oil pump gear, compromised?

[@highlandcycles]

No oil pump on 2T

[@seamarsh3756]

Geez I must have been tired last night haha

[@ericbulic8589]

Morgan check out Rock Mounts for timeserts/helicoils. If you are still in the market. They would work for you I think

[@cplandrew]

Really glad that you salvaged it! Here's hoping the first ride doesn't reveal any failures! Good to know that it can be run that hard and still fixed!

[@2WheelsandtheGospel]

I love it when a plan comes together! Glad it worked out.

[@Danman1972]

I've had the tusk one for about 75 hrs. It randomly fired on me a few times getting the tank on and off recently. I think it maybe the sensor wire. Likely going to replace that. the sensor itself came loose and I did a lop of stainless safety wire on it. Also, will be install a relay that keeps it from firing with the bike off. Not 100% sold on the idea though as it does run a bit after I shut it off sometimes. Mostly if it's over 75 or 80 degrees ambient. I have also noticed the temp reading on the controller is wonkey sometimes. again... likely the sensor. I've not had any issue with the controller yet. I mounted it along the left side of the frame right in front of the tank.

[@randytidwell5836]

did it have a high compression head on it? just curious.

[@highlandcycles]

Yes

[@richardhartley7094]

You dodged the bullet yes but look out it may ricochet 😩great video👍

[@joshshelton796]

Awesome video man!

[@JamesBurr-vk7kh]

Way to go!!!🤘🤘🤘🤘🤘💯

[@runner0092]

Very happy to hear American aquarium in the background

[@highlandcycles]

🤘🏻🤘🏻

[@brendonchase9460]

Nice ❤

[@TheOutsideDev]

Another great video. How can I become a member? I don’t see where I can do so, anywhere on your channel/page. Thanks !!

[@highlandcycles]

Huh. Somewhere on the page while you’re watching it should say join.

[@TheOutsideDev]

@@highlandcycles I can see where the join button should be, it’s visible on other channels. For you sir I cannot see a join button anywhere. I’ve tried logging out and back in, made no difference. Strange !!

[@highlandcycles]

@@TheOutsideDev that is odd. I’ll check my settings

[@highlandcycles]

@@TheOutsideDev where are you located? There are some restrictions for location (by KZbin, not me).

[@TheOutsideDev]

@@highlandcycles I’m in Canada

[@MrJacksmithFTW]

you should check your clutch dampers

[@highlandcycles]

I’ll be checking everything

[@JasonRoberts-wh1np]

🤙

[@2WheelsandtheGospel]

🤘

[@1176hambone]

the o-ring seal will not be sufficient. it will fail

[@highlandcycles]

We will see

[@stacksmasher]

Wait you overheated with a fan on?

[@valeriel1292]

I believe he didn't have a fan installed.

[@onthethrottle7104]

no, he did not have a fan when overheated.

[@Josh-Silvia]

40:1 crowd checking in!

[@highlandcycles]

❤️❤️

[@artsteale3443]

Don't use heli coils Use timeserts they are way better. Oh I see you are using helicoils......good luck.

[@highlandcycles]

No room for the time sert in this application unfortunately

[@artsteale3443]

@@highlandcycles I put heli coels in my 200 cylinder years ago it's holding up but you can feelsome binding in the threads.

[@Dirt_Bike_Dave]

Morgan..I hate bagging on bikes...but with all the problems you've had with this one..I'd get something else...sorry man. I pray it stays together thus time.

[@highlandcycles]

Hahahaha. I haven’t had issues until recently. It has 260 hard hours. Before the recent stuff it was all aftermarket failures. I think it’s been pretty reliable compared to a lot of customers bikes

[@woodysrockspyro6436]

260hrs... My 2023 sherco has that now. Poor thing. On my 3rd piston maybe. Waited too long to start 175hrs.. then at 220.. got water in it. At 240. Then my son put straight unmixed fuel in it at 250. Just changed the rings on that hit. Still doing good. Thinking about putting a bottom end in it next time. Might be rattling a little more than usual.. who knows I'm hard on stuff. Funny once ya get so many hours on something ya decide to keep it forever. 😂

[@highlandcycles]

@@woodysrockspyro6436 my goal is 1000 m this