Bike Builds
KTM 300 XCW / TE 300 / EC 300 2024-26
I know these bikes have problems. Not a lot of problems, but a few detrimental ones. Let's fix them, and then make it a great bike, for what most people buy it for. To have fun with a lot of bottom end power.
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July 24 2025. I just plunked down $10,499 for this 2025 XCW 300. The whole pupose is to fix all the KNOWN issues and then experiment with whatever to make it the best bottom end monster you can get.
The first thing I did was open the gas cap and look into to see how much fuel was in it. I was a little bummed to see a bunch of dirt at the bottom of each side of the tank.
I sent this pic to the salesman and said maybe the service guys should know they are filling these things with dirty gas. I just got a text back with a thumbs up, a LOL and a "good thing it's got a filter on it, huh"
I only share this so you you know, that you are most likely on your own, to make sure you don't have bike problems. And I'll do what I can to help you. Below you see some of the dirt collection.
The dirt is picky but worth pointing out becasue that seems to be the them of buying any KTM / HUSKY / GAS GAS nowadays. " If it's going to be a good reliable bike, it's UP TO YOU. With some help from us.
Along the way here, there will be our youtube videos you can watch as well, if you'd like. Here we go with the overview Video
Next we have the first vid on pressure and the crank seal problem
So above you see the common problem with the ignition side crank seals. They aren't in all the way and they are most always put in crooked.
The biggest issue with this is, seals aren't desgned to run crooked and if run this way, they could soon start to leak. And this is a really common problem, with the leaking. All we really have to do is just put them in straight.
I just use a 15/16" deep socket and a hammer and drive it in 1mm or .040". Like the pic you see here. Then I use gasket sealer on the seal to case junction. it's Permatex brand motoseal.
With the ignition side crankseal fixed ( and it's possible that the transmission side seal needs fixing too or the O ring behind the gear is missing ), it's time to move to the next problem area.
The SINGLE BIGGEST PROBLEM with these new TBI KTM'S is AIR LEAKS. The top end on a 2 stroke ( cylinder and crankcase area ) should be able to hold 7 psi of vacuum and pressure. That's always been a level on any 2 stroke since before your mom was born. The engine is then pulling all the air and fuel through the intake and any jetting for fuel can be correct.
With the new TBI engines, you have a crankcase pressure sensor tied to the top end. It's job is to monitor pressure in the top end. The pressure parameters are based on the engine being able to hold 7 psi of pressure
With the exhaust port plugged ( 2 " od rubber expandable plug. Or freeze plug ) and the intake plugged ( 2 " aluminum plug with 1/16" barbed fitting in it ), we check the pressure. Because the leak was so ba that the engine would not pump up and hold vacuum, we had to blow air into it.
A fuel pressure gauge was Tee'd into the line, so we could monitor incoming pressure. Air was blown into the engine with the air compressor nozzle slowly, while watching the gauge. At 3 psi, you heard the air escaping from the engine around the back side.
With soapy water being sprayed around various joints, you spotted the quick leak , where the crankcase pressure sensor fits into the rubber connector pipe. And at only 1 psi of pressure, the air was flyting out. See the bubbles below
