How to Rebuild the Top End in a TPI 2 Stroke (KTM, Husky, GasGas 150/250/300 Piston Replacement)

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This video shows the complete process to replace your piston in a fuel injected (TPI) two stroke by KTM, Husqvarna or GasGas. The steps will vary slightly depending on the model and engine size, but the overall process will be the same. The bike in this video is a 2020 KTM 250 XC TPI.
This top end rebuild was at 73 hours, and my piston and cylinder were in awful shape. I do not know if this was a result of something I did wrong, or if the bike was simply not getting enough oil. Regardless, I had to send the cylinder out to Millennium Technologies for replating. The bike is running strong after the top end rebuild.
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Idle screw mod on a TPI 2 stroke: • Idle Screw Mod on my 2...
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Chapters:
0:00 Teardown
4:02 Inspecting Piston and Cylinder
4:23 Assembly
8:55 Starting the Bike
10:05 Ripping Singletrack

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Опубликовано:

7 авг 2024

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Комментарии : 30

@HondasLittleRedPig 3 года назад

“Crows feet” for the hidden cylinder bolts, works great.

@romainberger 3 года назад

There are open ends adpater that allows you to torque down bolts that aren't reachable with a socket. You just need to calculate the new torque value. Cheers

@godthing88 2 года назад

Great video!!!!!!!

@KincadePavich 2 года назад

Thanks hope it helped ya out!

@user-sq8ul3nc1v 5 месяцев назад

Hi all way from Australia here mate love the channel very informative,was wondering if you could do a subframe removal and reinstall as there are no videos on tube covering this. I have a 2023 ktm 300 tpi. Let me know if this is an option. Appreciate it legend

@mustafanajm965 4 месяца назад

Thank u for the video i have question please i have this bike im going to repair the top end but what the different between oem top end and vertex top end please help

@lucasmonks5767 2 года назад

Do u always use ( M technology ) kustom kraft has had my cylnder for 7months

@sebastianpollok7234 2 месяца назад

Hi, which 2t-oil did you use the 72 hours? Always the same? Thank you for information.

@HESTEBAN915 3 года назад

Awesome video!! Can you do one for the kx250s

@KincadePavich 3 года назад

I don't have a KX250 to put a top end in unfortunately!

@stevenbarber925 5 месяцев назад

Is there a specific break in process you recommend for 2022 KTM 300 xcw?

@KincadePavich 5 месяцев назад

I would do 3 full heat cycles without touching the throttle while it warms up. Gentle riding for first 10 or 15 minutes after that, and then ride it like you stole it

@stevenbarber925 5 месяцев назад

Thank you

@teddyf9438 3 года назад

1:28 is classic

@KincadePavich 3 года назад

Hahah love you caught that

@teddyf9438 3 года назад

@@KincadePavich gotta watch every detail of the video because one day a 250xc of Austrian origins will be mine!

@andrejskamla9736 3 года назад

I am about to do a top end on my 2020 ktm exc 250tpi. I want to order all the parts (piston, seals, oil pump, oil screen and the power valve orings) prior to opening the engine since I want to ride it while I wait for parts. I want to order the same piston size as the stock one and then when I open the engine I will get the cylinder measured and if B piston will be needed, then I will return the A piston and buy a B piston instead. But chances are that A piston is what will be needed. Could you please tell me what the stock piston size is ? 250 exc/xcw has the same engine as your 250xc except the transmission. Thanks a lot.

@KincadePavich 3 года назад

Hi there, I ordered a B piston from Slavens since that's what they recommended for # of hours on the bike. But I ended up getting the cylinder replated anyway, so I sent the piston to Millennium with the cylinder. Best of luck with the rebuild. Sorry if this isn't a super helpful response!

@sweetvidzbyjoe 3 года назад

Nice video. Why was your piston/cylinder so scored? And no oil pump priming before restart?

@KincadePavich 3 года назад

I've been lead to believe piston/cylinder damage was due to a cold seizure. Bike never actually seized, but could have been improper warm up. I bought it used, so it could have been before I bought it but I really don't know. Ever since the rebuild I have been even more careful about letting it warm up fully before riding and making sure radiators are warm to the touch. As for priming, I believe it is only necessary if there is air in the line, such as in the case where you replace the oil pump. Maybe that is not correct, but the bike has been running great since the rebuild with no issues.

@richrevit6360 2 года назад

The oil pipe is attached to the intake system not the motor. So isn’t disturbed when doing a top end.👍🏻

@dirtyrider4214 2 года назад

What number gasket cylinder you use it?

@KincadePavich 2 года назад

I cannot remember off the top of my head... I can look back and see what I have left. I remember trying to match the thickness to the one that came out of the bike as closely as I could.

@donaldblank8873 9 месяцев назад

How do you know what size piston and rings to buy

@KincadePavich 9 месяцев назад

Look at your cylinder it's stamped with a letter

@thegan9143 2 года назад

Didn't see a deck measurement or measuring the power values setting??

@KincadePavich 2 года назад

Unless I'm mistaken not much needs to be measured with the power valve. As for the deck measurement, you're right. I used the closest cylinder gasket to stock and went with it. Didn't have the appropriate tools for Z height. Potentially worth investing in and something I should have mentioned. Hope you found it helpful otherwise!

@thegan9143 2 года назад

@@KincadePavich Definitely helpful. I've never done a top end before and it is time to do mine. The RMATV video had the additional steps of deck height measurement and power valve setting. I think you're correct, there isn't much need to play with the power valve setting. The tool for both is available from RMATV for pretty cheap though if you wanted to measure both.