KTM TPI 2-stroke Engine Bogging? CCPS issues, fixes and modification 

I have over 400 hours riding experience with the TPI bikes and can add a few points. The 2019 bike only has one sensor, and it is in the middle of the tray. This makes it difficult, but not impossible to replace without tipping the subframe and dropping the tray. I removed the cylinder head stay for more room and removed the tray securing bolts. The tray can now be deformed enough to access the sensor securing screw. Make sure you have the correct size torx tool. The 20-21 bikes are easier as the sensors are on each side of the tray. As mentioned, both sensors are the same part number, and in a pinch you can just swap them side to side. We have swapped out a bad sensor at Staging in the parking lot with practice. Order up a spare, we see these go bad as soon as 20 hours of operation. When they begin to fail, the bike still runs so you won’t get stuck on the mountain. The onboard diagnostic system will not tell you if it is failing. In our experience, only the Crankcase Pressure Sensor fails, not the Ambient Pressure Sensor. These sensors last decades on automobiles, but only months on KTM’s. I can’t explain why.

This is a fantastic modification 👍 I would definitely buy one if you start making them. Keep us updated.

As usual absolute fantastic video explaining everything that's why we love watching your videos, yes looks like KTM quality control is not so good I hope you're going to start manufacturing those fittings, keep up the fantastic work 😎👍🇬🇧

I love this kind of content. Very well made videos! As a recent owner of a 2018 TE300i, your channel is a gold mine! Thank you a LOT!

Nobody else makes such detailed videos with excellent quality video closeups on the parts. This is my go-to channel whenever I have KTM issues. Thanks and keep up the good work!

Beautiful brass fitting made by you . Too bad KTM did't think of this . Most owners may not be making this fitting. You make some of the best videos concerning KTM bikes , love it.

Mate, hello from NJ, USA!...21' TE300i here..I purchased your CCPS Fitting kit and the Quality and thought put into is pure Genius ..Worked out GREAT..Thank you! Cheers. Jim

Hey my wife got your oil change kit for our KTMs, it's a great piece of kit. Thanks for the vid, TPI isn't as good as carbs but it's what we have now. Cheers.

TAKE MY MONEY! Excellent video thanks. And I would definately pay for that fitting if you decided to sell them! KTM dropped the ball there!. Cheers

Back in 2019 I made the decision to buy the last year model of the carbueted KTM 250XC. Good decision confirmed. Thanks for all your good videos!

La durite de mon 300 tpi de 2019 était colmatée et il avait des ratés. Problème résolu grace a la video. La moto tourne comme au premier jour. Merci beaucoup 🙏

Amazing work!!! I was thinkin the same thing (using Silicone grease) on that o-ring when I seen it. On a new bike always good to disassemble check/grease ect.

I experienced the bogging as described on my KTM 300 xcw with close to 50hrs. I purchased both the tray and brass fitting. I installed them. It is a much better fit than OEM. It works great! Your videos are top notch-thx!

Excellent technical. You are my best teacher..!! Thanks to help with spectacular videos.

While I’m sure this is going to be more reliable than stock, I don’t believe the majority of CCPS issues are from leaks - they are from the sensors themselves going bad. I’ve changed enough of them, and heard from a lot of ppl, that simply replacing the sensor with a new one fixes the issue. I also experimented by bypassing the tray and connecting the sensor directly to the hose, and that didn’t fix the issue, but replacing the sensor did.

I appreciate your insight and fixes 🤘

A brilliant modification. I would be interested in purchase also :-)

Tokyo I enjoy your videos and have learned a lot, thought I might offer advice to help you for once. Some are spraying aggressive solvents (MAF, carb, brake cleaner) into the sensor in an attempt to delay problems or bring a dead sensor back to life. The sensor is potted from the elements, for a gentle yet more effective approach try a heated ultrasonic cleaner with water and 1/4 cup of simple green. Don't submerge completely, hang from the electrical connector. This approach should completely clean the spooge out of the sensing orifice.

Thanks so much for the information!

Thanks for that. I fitted the idle screw you sent me, but not the RK tek head. I have also fitted the GET injection and ECU kit. Good improvement, but I have a flat spot which will get sorted on the Dyno in Leatherhead. I have a GasGas EX300, the only one in the UK, I think.Through the gears it feels faster than my FX350 F, which I have worked on a lot.

What a legend! Thanks for your help!

My barb is bent just like yours, I shortened the hose so it puts less tension on it. Maybe the bending of the tray is putting tension on the sensor and cracking it around where the 2 parts are joined. Both my failed ones are still going after I glued them.

Just bought an 18' XC-W 250 W/ issues. Glad to find this. Just a thought: That CCP sensor hose looks like its designed for a high pressure hydraulic system. Maybe the stiffness of this hose is causing the deformation of the tray bung? Seems crazy at the small pressure differentials that this hose sees, that this beef is necessary. Maybe those small wire clamps are not sealing it? This is all new to me..

For those who might want to know: the CCPS sensor can get worse than a bad bog at higher RPMs, and prevent the bike from running entirely. I think a piece of carbon got sucked into mine and totally roasted it. Bike was inoperable past warm up. New sensor: bam, fixed.

Perfect video. Thanks a lot🙏

Great video content. Keep it up

Awesome video mate. I’ve also heard that every 20 or so hours spraying maf sensor cleaner into the pressure sensor helps delay any deposits stopping the sensor from doing it’s job. What’s your opinion on this?

Few people have the patience to meticulously explain things the way you do i would just love you to ride a yamaha 250fx then my life would be complete 😁

Hi Mark, Love your videos and hands on work. my 2021 300 tpi is having what I think is CCPS issues, bogging at low and mid throttle openings and can clear with a few revs, but the odd thing is it may not start doing this until an hour or two into a ride ! so being an intermittent problem is strange and difficult to diagnose. I swapped the two sensors around and the problem went away ...... well for at least 8 hours then started doing it again. .

Cool modification 👍

I thought I might have a failed CCPS. But, my sensors were fine. It turns out my issue was a very dirty spark arrestor screen. Crazy! Very similar symptoms that is described by the CCPS failing. I learned something new as this my first 2-stroke (I owned 4-strokes before) and I only cleaned the screen once. So it all clogged-up at about 75 hours. I removed it for a test ride and she's back! Used a torch to burn it off. It caught fire like a sterno can and burned for 2 minutes!

Let me know when it's up on the sites. I'm ordering one!

If I have low end bogging can this maybe be the problem. When I first got the bike 2021 xcw300 I could go up steep hills at almost a walking slow pace. Now steep hills I bog down on power if I don’t keep rpm’s higher

all that work and it could have just been a just a faulty CCPS, nice vid and thanks but to check it is sealed apply some air pressure and see if it holds, that will tell you if any of those point are leaking

Thanks for the video. Any chance you would be able to post up the crank case pressure readings (including your elevation) using the OBDI connector so people have a baseline?

Still can’t figure out how to even get to the trey and get the sensor out of my 2019 250tpi. I just spent an hour downloading the manual from some sketchy site asking for 10 dollar donation got 387 pages of words and zero pics. This is getting beyond ridiculous. I should of just kept my carbureted bike at least those you can work on.

Really nice design but i dont think it is needed. I was experimenting with different sensors and everything was much more dirty than yours but i didnt even bother cleaning it, just tried another sensor and it solved the problem.

This is why I love carbs, simplicity

I have a new 2024 300 XC-W in the USA (14 hours on it). I am having problems at low RPM. The bike runs rough as if it were cold, or lean. Looking online it seems that for the TPI models this used to be a Crankcase Sensor issue. I cannot find any information online to whether the 2024 TBI also has an issue with this sensor. Also, my bike is pretty clear with only 14 hours. Do you have any suggestions? I would greatly appreciate and lead.

The original plastic nose has a bend to reduce hose bend and prevent hose from cracking.

More reason to hang on to my trusted carburated 300.

I have a 2020 TE150i with 40 hours that had a similar issue. Was bogging down low, acting like it was not warmed up. My CCPS had failed. Ran the bike for 1 hour with it failed ( just easily, not hard at all ). It badly scarred my piston and cylinder. Had to replace the top end.

5:07 Why would KTM use a sensor made to clamp into a manifold, and then adapt it with fittings on that plastic tray to suit a hose? It makes no sense when there are multiple pressure sensors available with a direct hose connection. Crazy You could use the MAP sensor from a Honda CRF as it is a remote unit with a hose barb. Almost all efi sensors run on the 5v modified signal and should work with the ecu

A couple questions. Looking at the video it appears the bike was at a pretty extream.up hill angle, cant really tell by the video but could it have been starved for fuel? Did the bike bog again on flat ground, or was that the only tome it bogged? You are using the same same sensor now right. And lastly could the gas cap vent line been plugged. Very interested in knowing what you find out cause i bought a Husqvarna 300i recently and its the first bike I owned that is not a Japanese brand.

Nice👍👍👍👍

Will you be offering this kit for sale?

Hi, great vid as usual. You mention a possible cross reference for the sensor against a car item, which would be handy at £100.00 each from KTM. Do you have any ideas regarding this as we've looked into it and can't seem to find a match? Thanks for any help you, or anyone else may give.

Mine is dead after 40h... I've cleaned it, was very dirty but after reinstalling it, wouldn't work better... guess i have to replace it.

Mark how about the ambient sensor. How will you know if its defective

Nice work Mark ,you should be working for KTM as a reliability engineer,I think I will stick with my Stic module in my keihen 👍D

Are you gonna sell those brass pieces for the rest of us😁

Queue the "im glad I have a carb comments" Nice vid, looks much better now

I had the same bogging issue. Swapped sensors and bought your brass fitting. Bike runs great now! If it was a bad sensor, why does the bike run great with what is essentially a bad Ambiant Air sensor now?

Looking for some advice! Any recommendations is very much respected! My 2020 ktm 250 tpi 250xcw bike with roughly 100 hours has never been worked on till I purchased it at around 70 hours. Other then a fmf fatty expansion chamber. When I bought the bike it ran perfectly. Then about a month later it started having a weak idle. It would die on a long downhill with the clutch pulled in. I done the idle screw mod in the bottom of the throttle body and got it idling good. Now I feel like the bike is bogging more in the low end. I adjusted the air bypass screw to where the bike feels the best an its around 6 turns out. I heard that is too many an something else must be wrong with it. The bike runs amazing on the high end. Iv heard of the crank pressure sensor giving people bogging issues but it was on the higher end of rpms. Mine seems to have lost the low end grunt but barley enough to notice.

We had German trucks full of sensors. Forever stuffing up. Good luck.

Hi, I have the same issue. Checked any block or leak on the system, and nothing found. Changed the sensor with a new one and the problem still appears. I've noticed the problem occurs whenever I reach higher altitude places. I have a 2019 tpi which only runs one crankcase pressure sensor, which the bike uses as ambient pressure sensor when the engine is not running. I suspect the problem is that the ECU is messing with the values recorded with this sensor and maybe its reading crankcase pressure and using it as ambient pressure? The problem appeared with 200h on the bike. How can I diagnose the ECU?

Hello. Recently purchased and received your modified tray. How tight shoul I tighten the aluminum bolt? Thanks!

Hey mate I have similar problem but once it bogs I can’t save it and it stops then I can start it right back up and it will do it again ? I’ve replaced the ambient sensor side, reckon I should try the other side ?

Hi my friend how are you doing? I’m having a problem on my 2020 Tx300i, it start very easy idle good but when open the throttle for a little bit it still good and when I keep opening it bogs, I went to my friend’s home yesterday because he has a 2021 te300i and we did a lot of different tests switching part like thank to test pump, injector, spark plug and and the ecu but it still repeating the same problem using his parts on my bike. So can you please Giv me an idea how to fix it.

Do TPI models reaally need all those troubleshooting? I am happy with my carbed TE300.

Anyone know which automotive manufacturers are using this sensor? This sensor is back ordered from Ktm for two more months....

In the middle of replacing all of this, do you know that torque specs for the brass vacuum bolt that goes into the cylinder?

I changed my sensor a couple times , but bike still was running crappy at low throttle. Ended up being the engine vent tube was clogged with white watery oil gel on the front of my engine.

KTM taske note !!

I heard that the crank case sensor fails way more often than the ambient pressure sensor. Would you recommend swapping the sensors as part of preventive maintenance on like 100h of riding time? Just to even the "stress" on the parts.

Hi are you going to do a video of how you modified the tray?

After 145 hours of pure perfection on my 300xc tpi………my ccsp finally shat the bed on me yesterday. lol.. mine fouled 2 plugs. Like it caused it to become very rich off bottom.

Ah I still can't decide whether I should get a KTM / husky / gas gas tpi or something like the beta 300 RR... This is essentially a carb Vs TPI argument I am having. What do you personally think Tokyo off-road??

2021 GasGas ex300. Sat for 8 months. Started each month, but no high revs, just idle. Bad bogging. Quick blips and over 1/2 throttle bogs. Changed all fuel filters, changed CCPS, and cleaned CCPS hose. No change. Any other suggestions? Fuel pump? Throttle position sensor? Any help appreciated

My 22 te150i is doing this at 17hrs.

Question, did you notice a change in the exhaust note when the sensor was busted?

I’m a die hard ktm fan but I think I’ll probably give Sherco a try when it’s time for a new bike. I’m old school and prefer fixing gas and jetting carbs over. Pressure sensors and electronics

Do you use the choke on initial startup?

Man i wish u lived next door

What do you think was the fix? You changed 2 things at once

I'm getting the impression the TPI bikes are going to be even more unreliable after 4 or 5 years, its a pity KTM doesn't offer the option of a carb. on bikes that are sold in countries that don't require TPI for emission control reasons eg. Australia

I love this channel. I have a 2018 250 tpi.. one time the bike cut out when I was racing the engine at high speed. It only happened once. It was almost like it lost spark, or had no gas... complete cut out... as if I was pushing the kill switch. I still don’t know why or what caused this... do you think this could be the pressure sensor? Thx so much for your great videos

I also had a ccp failure on my 2020 ktm exc 250 tpi but the sympoms were different. One day I started the bike and idle was way too low. It would stall on its own. And it was a bit boggy aswell but in a different way. It rode like a cold not warmed up 2stroke. It just wouldn't clear up until it got to top end. Btw if anyone wants to know the part number for the automotive sensor I can copy it here

has anyone been able to identify the automotive alternative sensor? i assume its a bosch sensor

Bro who are you? 😎😎😎. Made a barbed brass fitting from a solid piece of brass 😳. Make me one 🤣.

Do you sell that fitting

Take my money.

TPI owners. Has anyone experienced a low RPM stutter along with occasional pinging/ erratic top power on their tpi bike that wasn't related to the pressure sensors in any way? 22 te150i, 17hrs suddenly started running poorly. Everything from fuel pressure to electrical grounds has been inspected, checked compared and verified, along with everything in this video. I temporarily bypassed the tray and hooked new sensor up directly to the hose. I went ahead and replaced the ambient sensor, no change. Dealers want to mess with the power valve or change other settings that I'm not OK with because it ran perfectly until all of a sudden at 17 hours. Completely oem bike, untouched other than careful inspection. This has to be a unusual failure/malfunction.

Where did you find a new ccps?

You call that bad bogging, my 125 two stroke sounds like a four stroke half the time

I need you to make 1 for me

Best fix is buy Italian French or Japanese

Too bad you didnt reinstall the original sensor to see if all that work was worth it

Just bypass it all

These bikes are too complex.

What a shitty looking design. I hate sensors.

This video is a slog. for effs sake mate get to the point.

You should sell the components you make yourself they look excellent quality