How-To Rebuild a KTM TBI Engine: From Start to Finish

If you’re riding a KTM 300 TBI, eventually it’s going to need a proper top end rebuild. In this video, Tracy from Slavens Racing walks through a complete KTM 300 TBI engine rebuild from start to finish — covering piston replacement, ring installation, cylinder swap, and transferring the power valve assembly to the new cylinder. This isn’t a highlight reel. It’s the full process done correctly. Whether you're maintaining your own bike or just want to understand what goes into rebuilding a modern 300cc fuel-injected two-stroke, this video breaks down the key steps and details that matter. The KTM 300 TBI platform is extremely capable, but like any high-performance engine, proper service intervals and correct installation procedures are critical for longevity and performance. In this rebuild, we cover: Removing and inspecting the original piston and cylinder Installing a new piston and rings Proper ring orientation and clearance checks Swapping and setting up the power valve assembly Installing the new cylinder Torque procedures and final assembly considerations The KTM 300 TBI engine is different from earlier carbureted models, and attention to detail during a top end rebuild can prevent costly failures and ensure consistent power delivery. If you're searching for: KTM 300 TBI top end rebuild KTM 300 piston replacement KTM 300 TBI cylinder install KTM 300 power valve setup How to rebuild a KTM 300 TBI This video walks you through the process step by step. Slavens Racing specializes in KTM, Husqvarna, and GasGas performance parts, engine builds, and technical support for serious off-road riders. If you need parts for your KTM 300 TBI rebuild — piston kits, cylinders, gaskets, or service components — visit SlavensRacing.com. Subscribe for more KTM 300 TBI tech videos, engine builds, and real-world performance testing. Products used in this video: Top End Rebuild Kit by Two Stroke Performance: https://slavensracing.com/shop/top-en... Power Valve Alignment Tool by Bullet Proof Designs: https://slavensracing.com/shop/power-... EZ Clips by Slavens Racing: https://slavensracing.com/shop/ez-cli... More products seen in this video: TSP Cylinder Head: https://slavensracing.com/shop/cylind... Exhaust Flange Guard: https://slavensracing.com/shop/exhaus...