Got around to doing the top end rebuild on my 2023 KTM 300 XC TBI. This rebuild applies to all other TBI KTM brand bikes from 2023 and 2024 and onward, including the new XCW/EXC from KTM and the Husqvarna TE, TX and Gas Gas EC EX equivalents.
00:00 Intro/What I’m using
00:36 Battery info
01:03 tank removal/cleaning
01:37 Drain coolant
01:59 Plug/Hose removal
03:05 Electronic PV removal
04:08 Flange Guard removal
04:20 Head removal
04:30 Head inspection
04:40 Engine hanger removal
04:54 Cylinder removal
05:53 Cylinder inspection
06:21 Piston removal
06:41 Piston inspection
06:56 CCPS inspection/removal
07:34 Power valve inspection
08:09 Head cleaning
08:44 Setting Z dimension
09:43 Gasket removal
10:02 Power valve assembly
11:00 Ring end gap
12:06 Gasket install
13:02 Piston install
16:20 Cylinder install
17:34 X dimension setting
18:11 Head install
19:30 CCPS install
20:02 Hose install
20:28 Engine hanger install
20:40 Electronic PV install
20:58 Coolant fill/bleed
21:56 Power valve reset
23:13 TPS recalibration
24:38 Fire it up! Conclusion