2024 KTM 300 EXC TBI Top End Overhaul Part-3 Assembly

This is the third and final part of a 3 part video series in which I overhaul the top end of my 2024 KTM 300 EXC TBI.
Part 1- Disassembly, inspection and bore measurement • 2024 KTM 300 EXC TBI T...
Part 2- Power Valve rebuild • 2024 KTM 300 EXC TBI T...
Part 3- Assembly
A45030007110 I: Piston kit Gr. II MX 300 2025
Signet 13mm Torque Adapter: tokyooffroad.c...
TBI Electronic Powervalve Reset:
• 2024 KTM 300 EXC/XC-W ...
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Facebook: / tokyooffroad

[@wfodavid]

Great vid as always and thanks for the shock bearing vid. 65 years old and had more than 50 bikes and never had a shock bearing go out. Thanks again.

[@TokyoOffroad]

Pleased to hear that you enjoyed the videos.

[@dougderby9454]

Am so used to pushing the kickstarter with my hand slowly on these to get the piston on up in safely the rest of the way. Can’t with the newest. 😮.

[@TokyoOffroad]

Right. But using the rear wheel while in gear does work fine.

[@alang3991]

I believe with the latest firmware update on the ERM you no longer need to hold the throttle open 50% and turn the ECU off and on to adjust the power valve. You just go into the diagnostics module, select power valve reset, and press “learn”.

[@TokyoOffroad]

I haven’t updated my ERM firmware for a while. That sounds much easier. Will update it…

[@markaddy53]

great job as always lad keep it goin

[@TokyoOffroad]

Thank you! Will do...

[@pawesybirbia5231]

Great video. Big thanks. Greetings for You!

[@TokyoOffroad]

Pleased to hear that you enjoyed the video

[@trailsweeper]

could you plesa talk about washing all parts of the fuel system, tank to injectors , sorry for my English

[@ΜαριοςΚαρευθυμιου]

I have an sxf 250 2017 I change sparkplug and never runs again my compression is 60 😬

[@bingeciren]

At 160 hours my piston and rings were also within spec. I think these top end overhaul periods are way too conservative. Unless you are racing and spend most of your revs in the high end, these engines will easily go for 250 hours or more before needing an overhaul. My power valve benefited from a good cleaning but otherwise the cylinder, piston and the rings were in perfect shape.

[@TokyoOffroad]

Yes, the overhaul interval will depend on how hard you ride it, but also other factors like warmup procedure and air filter maintenance. The only part that looked like it needed replacing was the piston (wear on the skirt). Out of interest I just measured the old piston and it measures 71.886mm front to back at the skirt. This results in a clearance of 0.12mm which is greater than the wear spec of 0.1mm. As such for my use the overhaul period is not unreasonable and wouldn’t go longer. Not that I do tend to ride my bikes harder than I use to and also do more racing now.

[@damianmullin]

@@TokyoOffroad ...talking of racing, are planning any more of your race videos, loved the last one?

[@TokyoOffroad]

@@damianmullin Yes, the first race this year for me will be March 9 at the Kegon quarry in Kanagawa, Japan. I'll be sure to upload a video of the race...