KTM & Husqvarna TPI OEM Kickstart Kit Installation

This video shows the install of a KTM OEM Kickstart kit on to a 2021 KTM 300 EXC TPI.
Kickstart Kit Part # 55712945044
Tokyo Offroad BLS Capacitor Kit: www.tokyooffroad.com/product/...
KTM DDS Clutch Inspection Video: • KTM DDS Clutch Inspect...
KTM TPI Exhaust Valve video: • KTM & Husqvarna TPI Ex...
Webshop: www.tokyooffroad.com/
TShirts: www.storefrontier.com/store/t...
Facebook: / tokyooffroad

[@danieldoubleyou9784]

As an aircraft technician I have to say I love how clean you work and how clean your work area is. 👍👍 Greetings from Germany

[@JohnVanHolt]

I wish KTM would hire you to make these videos for us. Nobody does it better.

[@TokyoOffroad]

Thanks. But it seems like KTM’s recent strategy is that they don’t want their customers working on their own bikes as since YM2020 they have stopped offering the repair manuals to customers. Really bad move IMO and hope this policy changes soon...

[@JoshuaPfenning]

@@TokyoOffroad it certainly does seem this way. Push everything to the dealer seems to be the strategy.

[@JohnVanHolt]

@@JoshuaPfenning well, seems car dealerships make more money with service than new cars... maybe KTM is seeking the same.

[@paulsmithbc]

Thank you, I really appreciate you posting this! I finally got some instructions printed off and given to me from a dealer but the steps aren't very clear for someone installing this for the first time. I feel confident with the installation now that I can follow along with this!

[@ode4492]

Your videos are always a pleasure to watch and quite concise and informative. I have no plans to install a kick start on my MY2020 but regardless I watched this in its entirety. Thank you for taking the effort.

[@dickfitzinhole5600]

Would not have dared attempt this with just paper instructions alone. PERFECT tutorial. Sadly I wouldn’t trust my ktm dealer to do as good and thorough a job as me installing now that I have watched this. You are doing the KTM community a great service with these vids.

[@paisley3518]

You are an amazing instructor. You have given me the confidence to tackle this job myself. Thanks to your admirable attention to detail. Cheers and thanks again.

[@raindog314159]

Thank you for this, I ordered your capacitor kit and what is hilarious is that Wheels through Time is literally just across the street from me.

[@HackDiese1]

Thank you so much for the time and effort you put into this! Very well done and each step is explained in great detail.

[@davidmoline3834]

Thank you sir. I now feel comfortable installing the kickstarter kit on my 2020 xc. The factory instructions were very vague. Well done.

[@garydavey2303]

Thank you so much, just fitted a kick start and one of your capacitors to my 21 TE300i down here in New Zealand. Your video and instructions were perfect and it worked out awesome. Love your videos. Cheers

[@TokyoOffroad]

Great. Pleased that you found the video useful…

[@jonrasmussen5645]

As usual, fantastic video. Thanks for taking the time - your videos have helped me immensely!

[@SkankHardEnduro]

I installed a kick kit on my 2020 300 xcw yesterday and used your video starting and pausing step by step. Thanks for the videos!!

[@TokyoOffroad]

Great! Pleased that you found the video helpful...

[@kawikabrown2639]

Thanks you so much for all your videos you do a really good job explaining details and even give torque specs for the bolts and whether or not you use loctite or anti seize very thorough explanation. Much appreciated! Mahalo🤙🏽

[@jamesg7745]

Excellent video like usual from you! Your demeanor and instructions make the videos enjoyable, Thanks!

[@rl7880]

Wow! You are a KZbin treasure. Really nice work. Well done, sir.

[@CW-up7xv]

Excellent video as usual. Fyi I bought your wheel bearing press and used it a few months ago and it worked excellent. Also used it to press in the wheel bearing seals and it did a great job. Did it on 2 sets of rear wheels. The second rear wheel was an aftermarket tusk wheel and by heating the hub and freezing the bearings they fell in without even needing the press (tusk has 2 bearings on the left side). I used a heat gun and a lazer temp gauge on the hub and it worked flawless. Skf seals and bearings.

[@TokyoOffroad]

Thanks and pleased to hear that you enjoyed using the wheel bearing press tool. Thanks again for your business. You've just reminded me that I need to get a laser temp gauge. Handy things to have when you need them...

[@sdynak]

Thank you so much for this and all your videos. Really made it nice to work through my install over reading off text. Now I need to order the capacitor kit! :)

[@TokyoOffroad]

Pleased to hear that you found the video useful.

[@sbrothers7145]

Thank you so much man I have been working on my ktm for three months now!!! Huge help

[@TokyoOffroad]

Pleased to hear that you found the video useful.

[@midlan6]

love your work! following all the guide details, torque specs etc.!

[@kimojon9665]

Outstanding video as usual. I have a 2019 300 TPI, so I believe it was the last year they kept the kicker.

[@mcjustlikenew]

That was the best video I’ve ever watched how to fix a dirtbike very very clear and no bullshit talking right to the Point

[@TokyoOffroad]

Thanks and please that you enjoyed it!

[@gupomper]

Thanks for making this video. Really good quality!

[@knights518]

Awesome how to video. I’d like to do this to my 2020 over the winter

[@wfodavid]

Beautifully Done! Not sure I'm going to do this. That said Ill get stranded on next ride.... Merry Christmas.

[@mh6000]

great video. Trying to decide IF I want to install one on my 2020 300. In the past I've installed a kickstarter on a DRZ400. Very similar process. I especially liked your idea to create a cardboard layout for keeping track of bolt locations.

[@bdeer8089]

Beautifully done! Many thanks.

[@hackgolfer7352]

Very knowledgeable! Great video. Glad my bike has one installed

[@TheDirtbikeRider]

Really amazing quality of this video ! Tnx for it i will need it when i get new 2021 bike

[@TokyoOffroad]

Glad you liked it!

[@billyryder501]

Buy the kit follow te video take your time it’s like having insurance in the woods I have a 2020 and love it

[@hardendurobosnia17]

Hocel biti ktm 😜😆

[@bretpoole3179]

Just finished installing the Kickstarter kit in my 300. The video was great and super helpful. Wish KTM would come with kickstarters from the factory. This is my third 300 and had starter issues with the other two.

[@jawknee21]

How long did it take?

[@bretpoole3179]

It was about 3 years ago. Failing memory says about 2 or 3 hours and a six pack. On the third season on my 2021 and have not needed to use it.

[@jacobmace5301]

This video was fricken awesome, love it!

[@billyryder501]

Thanks it worked out great took me a little while it works fine now I have not to worry in the woods many thanks 😊

[@TokyoOffroad]

That's great. Hopefully you found the video useful...

[@saiinth]

Great video ! Just wish that ktm and husky would include a Kickstarter with the 2020 bikes and forward 😭

[@user-nf6qc8nd1n]

はたた たら

[@adriandewey1742]

Amazing job and amazin instructor ! new subscriber

[@leifkillman8708]

Good vid mate great detail

[@telestroud]

Followed the video and it went in perfect! 🙏

[@TokyoOffroad]

Great, pleased to hear that the install went smoothly

[@rodk.3569]

Great vids. Im buying one soonly. My 97 needs updated. Mainly e start!

[@rickpatterson8976]

Great video! I just installed a kick starter on my Husqvarna 2020 TX300i. I waited five months for a service manual to become available from my local dealer. Finally had to give up and the parts department was able to provide a PDF of the installation instructions. They were not as detailed and you video, but were adequate for the install. Even with an excuses of COVID-19 causing a delay, 2021 bikes are out and I still can’t get a service manual for my bike. This is a dirt bike and will require regular maintenance. If I realized that KTM and Husqvarna would not be able to supply a new owner a service manual I would have probably chosen a different manufacturer. Luckily my local dealer has been very accommodating when I call for specific details or specifications (torque specs) and will provide them to me over the phone. Seems like a shame that I have to wait for someone like yourself to provide a video on KZbin to get detailed information. Thanks again for your information. The capacitor kit and battery connector work great as well. I did cut the connectors and merged them into just two connectors to minimize the bulk of connectors at the battery. When in need of additional parts you will get my order and I have subscribed to your channel as well to try and say thanks with something more than just words. Keep it up, we are interested and watching.

[@kevingtoes9453]

Thanks for the video, it made installation on my 21 GG a breeze.

[@TokyoOffroad]

Glad it helped!

[@garywinkworth3380]

i had to watch again. your like me when you work so clean and careful. the bike shop wouldnt be as careful. its sad that they dont put kick starts on bikes anymore. after all its what bikes are supposed to have.

[@garywinkworth3380]

job well done very interesting to watch thankyou so much.

[@JAVTROOPER]

This is the first time i watched a tutorial video say newton meter and not foot-pound.. niceeeeeeee 😉

[@EC-xo4ti]

If you watched any of the footage from day 4 of Red Bull Romaniacs, you will see Graham Jarvis kick starting his 2021 Husky te300 several times on the side of a few hills, headlight busted and assuming a blown fuse as a result of a crash. This is a valuable how to video, in anticipation of a get off injury where a bump start would be very difficult. Thx

[@TokyoOffroad]

I just quoted your comment in reply to reubs91. Pleased that you enjoyed the video...

[@NirHason]

Great video! I need to take mine apart so I'll just watch this video in reverse :P

[@alsner1]

Great video first off, I just finished installing mine on my 2021 husky tx300i. But it is giving me massive kickback almost every time.... electric start is fine, nothing has changed there and the bike runs exactly the same. What am I missing here? Any help would be great

[@andrewsoldan6050]

wonder is installing kick start on 17' 500 exc-f would be similar?

[@l8starterl8starter55]

Interesting the weight is only 670g, I thought it would be more as I heard they deleted it for the weight saving. Maybe it was more so there cost saving like you mentioned.. I rarely use the kick start on my 300 but would like the option on my 17 500exc for piece of mind on longer rides. No need for a manual with your excellent installation guides, thanks again for sharing :)

[@richardhartley7094]

Excellent video 👍🇬🇧

[@kenwert7512]

Can you tell me if that kick start shaft is hollow? My kick starter bolt snapped and I’ve now snapped 2 ez outs. Wondering if I can completely drill out the bolt and retap or if by doing that my fillings will be able to fall into the case.

[@monton5440]

Great video , I would like to remove Kickstarter from my te300 2019 . starter is reliable living in tropical climate and want to reduce some weight ,pressure of the extra gears on starter. Is it same way ? Thank you !

[@macdemarco1476]

Is this the same exact process for the Ktm 500 exc-f 2019

[@carlatamanczyk3891]

What the manufactures charge for their toys, the machines should come with a kick start like they used to for the last 100 years. And the capability to start with or without a battery.

[@ronaldliebendorfer9009]

20t Press for a Sealing :D nice video good Job

[@TokyoOffroad]

LOL. Yes, you certainly don’t need a 20T press for the seal install, but using a press on this type of seal is so much easier than trying to hammer it in (which often can result in failure if the seal gets canted). Another way to do it if you don’t have a press is to use a use a bolt and some suitable washers, or press head and washer on the reverse side.

[@GerhardMair-qq3xk]

perfect instruction !!!

[@mgmgomez7658]

AMAZING !

[@pequeno1114]

Can You put a kick start on a KTM 790 adventure S? Thanks

[@alexdamron3170]

Coming from my 20 year old cr125 all of this is just wild to me I’ll stick to the old simple things

[@brandonwood6900]

Do you have a link to the small torque wrench you are using?

[@frankneikes]

Olaf amigo! Im Stück in Brazil with a starter motor problem! Now I can get a 350 exc 2017 kickstarter set! Will this fir my 500 exc 2017 I can see that the seal is not the same but the rest looks pretty similar! Can you advise or know someone with the answer? I can't import to Brazil as its not possible please help! Thanx my friend its Frank Neikes

[@joejohnston471]

Great Video !! About to install one on my 20 TX. I will say though that my Dad would rise from the dead to kick my ass if I used a screw driver as a chisel :)

[@GnarlyChicken]

Tokyo Off Road...Just bought a new 21 Husky tpi TE300i....dealer installed kick start for me. The bike WILL NOT kick start when cold...not even with the cold start pulled out. It doesn't even sound like it's getting fire. E start works fine, and can kick start after bike is warmed up..but still takes 4 or 5 kicks. Bike is bone stock with the latest flash for extra oil on start up. Any suggestions for me?

[@TokyoOffroad]

My kickstart at the end of the video was after the install and with the bike cold, so it definitely works. Not trying to be funny, but how is your kickstarting technique? Have you kickstarted other bikes, or is this your first time? If it's really a problem with the bike, as your dealer fitted the kick starter why not ask them to figure out what the issue is. Obvious things to check are the sparkplug, airfilter, fuel pressure and reed valve petals. How does the bike run when you've managed to start it?

[@therealgabber]

does this work for the 350 form 2018 too?

[@jsihavealotofplaylists]

How much do you think it'll cost to convert a bike with just e start to kick start?

[@dusty6345]

Thank you!

[@stone4858]

Awesome video, thanks for sharing 🙂

[@jessarellanes6648]

Great job ty.

[@baldknobby]

Does the exhaust valve cover leak on your bike?

[@codybollinger92]

What torque wrench do you use?

[@apiazza63]

Great video! Just installed one in my 501. Noticed a slight whizzing sound coming from the new starter gear while running. If I push in the starter shaft I can get it to stop/minimize it. But not sure if I need to completely disassemble and check it out. Everything works just making a subtitle gear noise. Any thoughts?

[@apiazza63]

Figured it out. The kick starter needed to have its position adjusted on the spline.

[@TokyoOffroad]

Pleased to hear you were able to figure out the issue.

[@damolux3388]

I wonder what else ktm will take off their bikes and then make available as an option?

[@drjekyll808]

@tokyooffroad did you notice if you had the 19 power valve seal or the leaky 20 version. I have a 21 as well and look forward to your videos. 👍

[@TokyoOffroad]

Mine hasn't leaked so far. Keeping an eye on it...

[@crazybalony]

Amazing video! Little question: on the 2022 300 XCW, I would need to install the capacitor AND the protected 9v harness to be able to kick-start and/or bump start?

[@TokyoOffroad]

Pleased to hear that you enjoyed the video. Yes, for a 2022 300 XCW fitted with a kick starter I'd recommend a BLS capacitor and the 9V precharge harness. For bump/hill starting just the BLS capacitor on it's own will work fine and allow the engine to start and run with a completely dead battery. However, for kick starting using the Precharge harness and a 9V battery will making starting more consistent.

[@crazybalony]

@@TokyoOffroad you'd think that KTM would minimally install a capacitor to bump, if the only means to start the engine fails...🤦🏻‍♂️any way to save money, a $5 capacitor...

[@crazybalony]

@@TokyoOffroad also, another little question, by adding all types of ear loops to the battery terminals, the screws end up falling short. Just changing them for longer ones would do the trick? What do you reckon the tread/pitch is?

[@eliadams9189]

Hey man do you have a link to purchase this kit?

[@Evgeny-sx5fv]

Great job!!! I was made the same, but kickback was very strong! What can be wrong???

[@jamesgriffith6033]

Same here, very hard to kick.

[@CrTopher_]

@tokyooffroad is the repair manual different from the owners manual? May be a dumb question!! Thanks for any other brilliant step by step video. Also you bike is pristine clean what's your secret!!! Cheers

[@TokyoOffroad]

Yes, they are different. The owners manual comes with the bike (also available online) and covers basic information. The repair manual covers all maintenance work on the bike in detail, including full engine and suspension overhaul.

[@hardendurobosnia17]

Its easier to kick start i bike with a capacitor, my 2018 xc-w tpi bogs for a second when i start it

[@erentopuz580]

Great 👍

[@ridingwithbaz2736]

i just rebuilt my 2011 ktm 300 motor top and bottom end all casing seals replaces, what's interesting is i used a thin layer of bel ray waterproof grease on all the housing seals like super thin and then put it back together as recommended and i have Zero leaks and when it comes to taking a casing off i can reuse the seals if they not damaged, i find the engine build of the 2011 motors to be more robust than the 2019 and up models and a little easier to work on, interestingly the 2021 crank can be fitted to the older models if you change the fly wheel. i cannot understand why ktm has made the new models so expensive and so striiped down, ie no radiator fan, kickstarter and so on.

[@goodboyringo9716]

I thought this to be a great video , more than I can say for the dumbbell that gave a thumbs down , ggg . Not one thing wrong with his instructions or technic .

[@nvmcrider8475]

Great video! I'm sure you know this, but in case some of your viewers may not, the snap rings have a square and slightly rounded edge, just like the non fiber clutch plates. Install the square edge side so that the force applied to it will use the square edge to retain the ring to lessen the chance of it popping off. Would it kill KTM to install this kickstart from the factory on their 10,000 dollar bike?

[@TokyoOffroad]

Yes, I forgot to mention about the snap ring square and rounded edges (I normally do in my videos). I was running late and need to get the bike ready for the ride the next day...

[@nvmcrider8475]

@@TokyoOffroad You have some of the best how to fix your bike video's on youtube, keep up the great work.

[@romy7533]

Hey my kicker recently started lightly ratcheting when I’d push in on the shaft. I pulled it apart.. return tab and circlips were in properly. Notches lined up. Tab on ratchet goes in behind the return tab all the way. But when I spin the gear it’ll still lightly ratchet. The one thing that stands out is that the gear on the shaft has some play to it. Both back and forth as well as I can twist it off axis (like when your wheel bearings need replacing) Is this normal or do I need a new needle bearing?

[@romy7533]

Note: I can’t see any visual wear on any of the parts aside from where the ratchets were making contact

[@desertrat250]

Hey Romy - I'm having the same issue all of a sudden on my '21 300 XC-W. Trying to diagnosis the problem but can't figure out exactly what's wrong. Were you able to resolve the issue?

[@dimencionable]

good morning ! Great and meticulous work: what dynamometric do you use to torque to 7.4 foot pounds? greetings

[@TokyoOffroad]

Al the Torque wrenches I have are made by Tohnichi and from the QL-MH range. Mine are all Nm: www.tohnichi.com/product-category/torque-wrench/adjustable-click-type/ql-mh-ratchet-head-type-adjustable-torque-wrench/ To set 10Nm (7.4 lbft) I use QL-50N-MH (3/8 " drive), or QL-10N-MH (1/4" drive)

[@dimencionable]

Thank you very much for all the information! take notes

[@buernbengel5427]

Hello, I Hope you can Help me. I want to reinstall the Kickstart into my 2018 300 tpi. But wenn I turn the kickstart it makes a "rubbing" noise because the teeths hit each others. I only took the whole kickstart out and did not undo the parts of the kickstart 🤔

[@buernbengel5427]

It's not as quiet as it is in the Video at 20:15

[@TokyoOffroad]

So you only took the kickstart lever off? If so nothing inside should have changed. But if it's not operating correctly my recommendation is to open it up, inspect the parts and try to identify where the problem is.

[@Jacare1973]

So you have to remove the whole clutch assembly because there’s no idler gear in behind right? Good vid!

[@TokyoOffroad]

Yes, that's right. Pleased that you enjoyed the video.

[@jawknee21]

I have a 2020 300 xc tpi. Do i need a capacitor or precharge cable?

[@TokyoOffroad]

Thanks for your interest. If you want to be able to reliably kick start your TPI with a dead battery you'll need the BLS capacitor with the precharge harness. This allows for connection of a 9V battery. I recommend not connected the 9V battery normally, only connect a fresh 9V battery when your main battery dies and you need to kick start it. The harness has a diode internally which protects the 9V battery for overvoltage from the bike charging system during use. If on the other hand you only want to be able to bump/hill start the TPI with a completely dead battery the BLS capacitor is all that's needed and the precharge harness is not required.

[@jawknee21]

​@@TokyoOffroadthe video says the xc model has the capacitor from the factory. Does it not?

[@KDXXREXCXR]

GREAT VIDEO. I just bought a new 300 XC W TPI 2020 and I NEED THAT. ¿Where can I get the kickstart kit?

[@TokyoOffroad]

Pleased that you enjoyed the video. The kickstarter kit is available for purchase/order through any KTM/Husky dealer.

[@KDXXREXCXR]

@@TokyoOffroad Thanks, but no every dealer offer de kit. No in Mexico

[@asbestosiscancerous]

what happened to the 2017 ktm engine build? or the whole bike

[@TokyoOffroad]

I built up the other 2017 250 I have and have been riding that. My rebuild 2017 250 will turn into a 300 and I plan to complete it at the end of the year. Will be sure to make some more videos about it...

[@gotdirt66]

T.O will the kickstarter not work without the capacitor? I have the kickstarter installed and the engine turns over but will not start. I order the capicitor/battery kit from your website

[@TokyoOffroad]

For TPI bikes, if the battery is completely dead, my testing showed that kick starting will only be reliable if a BLS Capacitor and 9V PreCharge used. For hill/bump starting with a dead battery only the BLS Capacitor is required for the engine to start and run.

[@ktmsingletrack2212]

I've been in a position where the battery dumped on my 450. Bump start was out of the question due to the terrain, so a back up kick starter is actually pretty damn handy.

[@fjgarageph]

do you ship to philippines? or australia? thank you

[@TokyoOffroad]

Thanks for your interest. Yes, shipping to Philippines and Australia is no problem and the shipping cost is calculated automatically on checkout in the Tokyo Offroad webshop.

[@midlan6]

btw I have 2019 model and I am going to remove the kickstarter :D I don't see any reason to keep it there if I am having battery + electric starter. The other option would be to add capacitor, and remove electric starter + battery. I don't like the bike have two starting mechanisms, it add extra weight. Just keep one of them. If you are in trouble, you can bump start the bike.

[@robertclarke1825]

Hi mark I have a link for the owners Manuel if that’s any good? 21_3214220_en_OM.pdf

[@richnewman6348]

5:32 you’ve got a 🐻 bear in your workshop 😂. Great informative video once again. Thank you 🙏. Stay safe.

[@TokyoOffroad]

LOL. That’s Max, my trusty workshop helper (11 year old Irish Setter)!

[@richnewman6348]

@@TokyoOffroad 😂😂 wonderful 👍 take care

[@Sustrii]

I will buy a ktm again when they go be independent again till then i will keep pumping Betas and im not alone on this so

[@timbermeister]

Would you mind telling us roughly how much the kit costs? I’ll do it myself if it’s not too exorbitant. Great vid btw. 👍

[@TokyoOffroad]

In the US the kit (KTM Part #55712945044) retails for about US$245

[@AzaisBaptiste]

hey great video! how to get workshop manuel??

[@TokyoOffroad]

I purchased it online from KTM. This video shows how: kzbin.info/www/bejne/fGKvlZevjtSDZrM

[@AzaisBaptiste]

@@TokyoOffroad great, thank you for your answer

[@hardendurobosnia17]

Did it come with a green spring

[@TokyoOffroad]

No, the stock spring fitted in TPI bikes is the yellow spring (considered the medium spring). No other springs are supplied with the bike, or recommended by KTM.

[@l.s.tukbigbud7715]

Is there anyone in the UK that could do this job for me.. please..

[@acn-6264]

Is the lever made of aluminum or steel? And if its made of steel does anyone know if i can buy it alone?

[@TokyoOffroad]

The kick start lever is aluminum.

[@acn-6264]

@@TokyoOffroad First of all, thank you for answering. I'd like to ask if you know any made from steel. Mine (from a new bike) is made from aluminium and I broke it after 3 or 5 times of using it.

[@keshmo12]

Wait so you can't even buy an oem repair manual for a ktm? That's silly because it has all the fluid capacities and stuff. I guess they just expect you to take your bike to the dealer for an oil change. Wish Honda offered a kickstart kit for my CRF450L but I haven't had a problem with electric start yet!

[@kirkthepimp1]

Well got a 130hrs on my clutch 😳 maybe it’s time for a clutch? Feels good but better safe than sorry

[@niklasbulling2987]

204hrs On my 2018 TPI Clutch ;) Still going strong but feeling bit off difference... anyway :D

[@kirkthepimp1]

@@niklasbulling2987 yeah honestly mine feels great probably do it at 150hrs I’m not to hard on clutches!

[@daph7017]

how do you know what you need a clutch?

[@TokyoOffroad]

For the riding I do 150-200H seems to be a good interval for replacing the clutch. After this time the fiber plates tend to be close to the minimum limit. But it really depends on how much you use and abuse the clutch while riding. I’ve heard some people get 500H plus from their clutches (probably rarely slip the clutch while riding), while racers get through clutch packs like hot suppers ;-) But in general my impression is that the majority of riders experience very good clutch life and performance when using OEM clutch packs.

[@TokyoOffroad]

When the clutch starts slipping it’s typically time to replace it. But my recommendation would be to periodically inspect it, measure the fiber plate thickness (make sure within spec) and replace before it’s completely worn out. In this video I talk about what I look for when inspecting the clutch: kzbin.info/www/bejne/eJapf36JbrioZ9E