KTM 300 Bottom End Rebuild

[@OversizedEnduroGuy]

You my friend are a legend Rebuilding my 01 300 exc Buttom end bearing blew out and this is the best video I've found, looks pretty much the same besides the stator side and outer covers 😂

[@highlandcycles]

❤️

[@Lewis_8]

Doing my 02 300 exc now too. I did a full rebuild 10 years ago so it's about time I did it again 😅

[@stephencrisson3595]

I love how you actually brought up the fact of not whacking the crank because you can distort it by moving the crank webs it's a big problem that people don't understand they can shift if u hit it just right very good video man!!!

[@anguspinkerton8637]

Most informative video. I have been following this video step by step, you certainly know your stuff! Thanks heaps for the video 😁

[@highlandcycles]

Glad to help

[@n.e.b.laaron9075]

You’re my type of friendly mechanic ❤

[@guttman]

Awesome video!

[@kyleunhassobiscay]

Thank you for making this! I bought a 2009 ktm 250xcw and it’s my very first ktm after riding CR’s my whole life. The ktm service manual is very vague.

[@highlandcycles]

Great to hear!

[@PowerlabsDiesel]

Rebuilt my kids bike using your video ! Thanks !

[@highlandcycles]

That is awesome

[@WhiteOwlBars]

kickass video - doin mine tomorrow & wanted to see what I was up against. with this video - i got this

[@highlandcycles]

Heck yeah! You’ll kill it

[@ianjones7526]

Hey hoping you can give some advice. Took my flywheel cover off today to look things over. It’s a 24 300 and there is metal flakes inside the bottom of the cover and magnetized on a few bolts behind the flywheel. The bendix looks like it’s maybe worn slightly and hoping that’s where the metal is coming from. Was planning on replacing the bushings anyways but is there really anywhere else for it to come from? The flywheel itself looks good and from your video it looks like there’s a seal behind the flywheel. I know I hit that stupid dual start/stop button a few times while the bike was running and have since replace the darn thing with a new set of buttons. Appreciate your expertise. Thanks for the videos.

[@highlandcycles]

I think it has to be the bendix. There is nothing else in there that would cause that. Get the XRC bushings

[@ianjones7526]

@@highlandcycles Thanks for the advice!

[@Outdoorjunkie246]

nice video thanks. just wondering why you dont put the top end on when its on the bench

[@highlandcycles]

Great question. The main reason is that it’s much easier to tighten the base nuts and head bolts while the motor is in the frame

[@woutervannoord2306]

Great video! I was wondering why don't you heat up te inner race of the crankshaft cylindrical bearing, and then just drop it over the crankshaft? That's what I always do and then there's no need to use the press on the crank or the case. Also both engine halfs just fall into eachother without a press. Thats is actually how KTM says it should go!

[@highlandcycles]

I haven’t had good luck with that. I know there is a special tool to heat up and then hold that race so it heats up and you drop it on but I don’t have one. Since I don’t have that, I don’t have a way to hold it that I like. I worry that channel locks will damage it. I should probably just buy the tool.

[@woutervannoord2306]

@@highlandcycles ahh okay, I just heat it up in an over to about 150-175°C as per the manual, then it just slips on! Maybe give that a try with some old cranks

[@Bawdo.]

hey man im having trouble with my bottom end rebuild, when i go to snug the centre case bolts i cannot turn my counter or main shaft by hand, any thing i should go over in particular i just put all new fresh bearings in the cases

[@highlandcycles]

Dang. You need to make sure all of the washers are in the right place and seated. (Aka not hung up on a groove or something. Also make sure all the bearings are fully seated

[@SkankHardEnduro]

My buddies 2022 300 xcw engine case is cracked/split where the swingarm axle slides through on the sprocket side. i know the top end need to be removes but my question is: can that case be replace without taking the clutch basket side all apart? thanks for doing what you do, you make great videos. I learned how to rebuild my fork and top end from watching you.

[@highlandcycles]

Unfortunately man, it all has to come apart

[@SkankHardEnduro]

@@highlandcycles thank you for fast reply, if we are ever out your way I'm going to contact you to do some riding. keep up the good work n video coming.

[@PowerlabsDiesel]

Nice video !

[@highlandcycles]

Thanks

[@bussin7683]

Hey great video! What years is the bike

[@highlandcycles]

2008

[@Wathappn2u]

Do you have any idea where I get a charger for snap on impact like you have in the video

[@highlandcycles]

Only from snapon

[@joeyl1742]

Thinking about buying a 2015 250sx for $3000 sounds too cheap to me. Anyone got any advice?

[@highlandcycles]

Sounds pretty low but the good thing is that since it’s a 2stroke it would be pretty cheap to rebuild if something is wrong

[@joeyl1742]

@@highlandcycles Thank you. The video was very helpful, no bs just straight forward

[@blazter6489]

I like it.

[@highlandcycles]

Thanks

[@Mike-h1k]

The needles pop in .

[@danielleitner241]

Where can i buy a new cylinder for my 300? I can't find enything on the internet!

[@danielleitner241]

And in the wrench rabbit kit is no cylinder included

[@highlandcycles]

Daniel Leitner yeah that sucks. I don’t know if you’ve tried everything but it sounds like you have. I would see if your local dealer can “dealer locate” one for you.

[@danielleitner241]

@@highlandcycles thx mate! I try this out👌

[@AlwaysLucky420]

how long did it take you to finish the bottom end ?

[@highlandcycles]

I can usually rebuild a 2t bottom end in about 2 hrs. That is just splitting the cases, cleaning and installing the crank. That doesn't include building the rest of the motor

[@traviswilliams9455]

That is not how to put a crank in the cases. You might as well hit the cases together with a hammer. You need a crank installer tool. Your still putting an extreme amount of binding pressure on the crank pin. This takes the crank out of true. You got a big fancy press but you can't buy a $100 tool set to do the job correctly?

[@adambrown6930]

Can this be done without a press?

[@highlandcycles]

Yes. You have to put the bearings in the freezer and heat the cases to get them to drop in.

[@brianengineering9001]

If I had bought a whole kit with new bearings and paid this guy to install it and he doesn't install my new bearings because he felt like the old ones were ok, I would be pissed.

[@highlandcycles]

I discussed with the customer, charged him less money and gave him the bearings.

[@kanonymous6414]

Is it possible to convert a 2018 KTMxc to a SX transmission? Thank you

[@highlandcycles]

Yep.

[@sucapizda]

Motors are electric, ENGINS are gas powered. Just saying.