KTM and their sister company, Husqvarna, have made a name for themselves in the industry by producing some of the best off-road enduro bikes. Their bikes are consistent champions and are constantly getting competitive updates and new technology. This is something unique for two strokes, and something especially enticing for us.

Before we even got our hands on the TE300i, however, we knew there were some imposing issues. Enthusiasts took to the internet to discuss the perceived downsides of the bike, citing the excess of electronics, expensive initial purchase, and inability to adjust the power valve as significant downfalls. After putting the stock TE300i to the test though, we found that the supposed downsides really weren’t that significant at all. The bike could already perform, we just fine-tuned and personalized that performance with our selection of aftermarket parts. Follow along below to see what parts we added to make the TE300i a new favorite on the trails.

Motor

Husqvarna did a lot of things right with their TE300i, and the motor was no exception. The power was impressive, accommodating every skill level. So, when it came to building on the motor, we didn’t have to worry about getting more power, we just needed to worry about optimizing it. Adding a Rekluse Radius CX Clutch was the obvious choice for us.

The aftermarket clutch is one of their auto clutch models, offering better power transfer than the stock setup. With their EXP disc, an acting friction disc that can expand and retract with centrifugal force, the bike can essentially come to a stop without the clutch being pulled – and keep running. For our enduro bike, the auto clutch was just what the doctor ordered. Making up for rider mistakes on the trail improving oil flow, and maintaining cooler operating temperatures were just a few of the benefits. The adjustable slave cylinder that came with the new clutch was huge for us as there was talk that the OE seal on the stock slave cylinder unit could fail, potentially leaving you in a bad situation. With the new slave cylinder and seal, however, we gave ourselves peace of mind.

A clutch wasn’t the only thing that gave us better control of the power, we also added a full exhaust system. Altering the power just a little bit, the FMF Gold Series “Gnarly Torque” Pipe with the Turbine Core 2.1 Silencer did a great job.

Thicker gauge steel on the pipe provided durability, assuring us we could count on that extra bottom-end power longer. The silencer really completed the look of the bike as well, looking sleek while providing us with that spark arrestor that has long been neglected in stock Husqvarnas. Topping everything off with the Husqvarna Digital Radiator Fan Kit to keep the motor a bit cooler, we had our motor optimized for its rider and their style.

Protection

Next up, we had to add some protection to the bike. P3 was the manufacturer we went to, scoring a Carbon Fiber Pipe Guard and Skid Plate.

Both add-ons are exceptionally lightweight and incredibly durable, constructed of P3’s blend of fiberglass, Kevlar, and carbon fiber. Aside from P3, we also looked to Tusk. Their Universal Linkage Guard can connect to most skid plates, and therefore worked well with our P3 addition to prevent excessive damage to the linkage. We also installed a Tusk Brake Caliper Support with Disc Guard to keep the rotor protected and finish it with an anodized aluminum, factory look. The Tusk D-Flex Pro Handguards w/ turn Signals were a nice finishing touch and offered incredible functionality with excellent protection for our rider’s hands.

Drive

Another aspect we had to tackle was the drive system. We chose to replace our stock components with the Primary Drive Gold X-Ring Chain, Anodized Rear Aluminum Sprocket in blue, and Front Steel Sprocket. These aftermarket options fit perfectly, boasting longevity and improved performance.

They also added some personal touches to the bike with the new color scheme. Along with the new chains and sprockets, we also upgraded the counter shaft dome spring washer. After riding with the stock one, we noticed that it was losing its spring, so we purchased the improved Primary Drive washer as a replacement. A couple of other parts we chose to add were the Tusk Folding Shift Lever and Tusk Brake Pedal Replacement Tip. Constructed of T-6061 Billet Aluminum, both are made to be light, strong, and reliable. They also offer several color options, each with a bold, anodized finish.

Tires and Wheels

When it came to tire and wheels, we knew we wanted to start with the Tusk Impact Complete Front/Rear Wheel Kit. Those bad boys are a great value for their price point, and the color options helped us continue the customization of the bike. Also, for running a spare tire with the trials tire, the Impact wheels were the best choice. The standard tires we chose to run were the MX33 Soft/Intermediate from Dunlop. Brand new, the MX33 is the replacements for the MX3S, developed to improve upon the notable grip, shock absorption, and flexibility of its predecessor.

Shored up with Bridgestone Ultra Heavy Duty Tubes, we set up the tires to handle the varying obstacles of any trail ride. Additional enhancements included the Tusk Typhoon Brake Rotors and Enduro Engineering Axle Pulls. The front rotor was especially useful, giving the option of running the OEM magnet for the speedo, while the axle pulls allowed for easy and quick tire changes to get the trials tire on the bike.

Suspension

Continuing with suspension, we had to make some serious changes. The stock Xplor forks were okay, but they didn’t offer a lot of adjustability with the clickers. Noting this lack of adjustability, along with the fact that both the forks and shocks are under sprung for anyone over roughly 120 pounds, we decided to send the suspension to Dicks Suspension. A specialist in off-road suspension, Dicks was able to set up our suspension to fit our weight, skill level, and type of riding.

If we hadn’t done this, the bike would not have been so comfortable over the rocks, roots, and square edges commonly encountered on the trail, so we think the tune-up was well worth the cost and time.

To accompany the full suspension set up, we also installed the BRP Dampening Handlebar Clamp to dampen any vibrations and Scotts Stabilizer to give security in high speed areas.

Both were easy to mount, cleaning up the cockpit of the bike with the help of the Clean Speed Cable Guide keeping the throttle cables organized.

Street Legal

For us, our TE300i mostly gets taken on mountain or single track rides with some connecting roads in-between. Though brief, our time on the road needs to be legal, so we looked to the Tusk Enduro Lighting Kit to solve our problems. With the turn signals integrated in our handguards, the rear mini flush mount turn signals, the folding mirrors, license plate mount, and horn, our bike was good to go on the street.

We opted to use the stock LED taillight, just splicing its wiring harness into the Enduro Lighting Kit to give both a taillight and brake light. All components were tied together with the Tusk Compact Control Switch, controlling the turn signals, horn, and even offering a low/high beam option. Now, while this kit worked great for us and made out TE300i legal in Utah, it may not do the same for you depending on where you live. If you are looking to make your bike street legal, always refer to local and state laws to ensure you are complying with their requirements.

Body

Finishing out the bike, there were a few body parts we chose to add on, but also a few we chose to leave the same. The OE fuel tank was kept stock, its size and capacity already ideal for the length of our rides. We found the original foot pegs to be satisfactory as well, arguably some of the best OE foot pegs on the market today. Leaving those items untouched, we added just a few more parts to enhance the overall look of the bike.

The Acerbis Frame Guards and Attack Graphics Factory Seat Cover offered virtually the same protection and feel of their stock counterparts, just supplied a little extra grip and a lot more color coordination. Extra Tusk billet aluminum accessories like the oil filler plug, axle block, steering stem nut, and several others further tricked out the bike, giving it style and personality.

Wrap-Up

In short, we were already impressed with the TE300i before we did our build, but we think our additions took the stock wonder to a whole new level. With this bike, it was all about fine tuning, and the parts we added helped make the bike as personalized as it was powerful. Although there were some concerns with the electricals, pricing, and power valve, all doubt can be safely set aside. Yes, there are a more electronics than previous models, but they are easy to locate, easy to test, and haven’t caused any issues for us thus far. While the bike is more expensive, you have to remember that you are paying for convenience. Among other things, the bike doesn’t need to be jetted and you never need to worry about premixing. As for the power valve, we think it’s difficult to adjust because it doesn’t need to be adjusted – the power of the bike is already nothing short of impressive.

Comment

Tell Us What You Think

We think we nailed this build and love the parts we added, but what do you think? Any extra parts you would’ve liked to have seen added, or any parts you wish we had left off? Share it all in the comments below.

Parts Available at Rocky Mountain ATV/MC

Rekluse TorqDrive Clutch Pack FMF Turbine Core 2.1 Silencer FMF Gold Series Pipe, “Gnarly Torque”
Rekluse TorqDrive Clutch Pack FMF Turbine Core 2.1 Silencer FMF Gold Series Pipe, "Gnarly Torque"
Acerbis X-Grip Frame Guards P3 Carbon Skid Plate P3 Carbon Pipe Guard
Acerbis X-Grip Frame Guards P3 Carbon Skid Plate Black P3 Carbon Pipe Guard
Tusk Impact Universal Linkage Guard Tusk D-Flex Pro Handguards w/ Turn Signals Tusk Impact Complete Front/Rear Wheel Kit
Tusk Impact Universal Linkage Guard Tusk D-Flex Pro Handguards w/Turn Signals Tusk Impact Complete Front/Rear Wheel Kit
Primary Drive Alloy Kit Primary Drive Sprocket Bolt and Nut Kit Bridgestone Ultra Heavy Duty Motorcycle Tube
Primary Drive Alloy Kit Primary Drive Sprocket Bolt and Nut Kit Bridgestone Ultra Heavy Duty Motorcycle Tube
Dunlop MX33 Geomax Soft-Intermediate Terrain Tire Tusk Stainless Steel Typhoon Front Brake Rotor Tusk Stainless Steel Typhoon Rear Brake Rotor
Tusk Brake Rotor Bolt Kit Enduro Engineering Front Axle Pull Enduro Engineering Rear Axle Pull
Tusk Brake Rotor Bolt Kit Enduro Engineering Front Axle Pull Enduro Engineering Rear Axle Pull
Husqvarna Digital Radiator Fan Kit Tusk Motorcycle Enduro Lighting Kit Tusk Rim Lock Nut/Spacer Kit
Husqvarna Digital Radiator Fan Kit Tusk Motorcycle Enduro Lighting Kit Tusk Rim Lock Nut/Spacer Kit
Tusk Nyloc Axle Nut Tusk Kickstand Attack Graphics Factory Seat Cover
Tusk Nyloc Axle Nut Tusk Kickstand Attack Graphics Factory Seat Cover
Tusk Brake Pedal Replacement Tip Tusk Folding Shift Lever Tusk Clutch Lever
Tusk Brake Pedal Replacement Tip Tusk Folding Shift Lever Tusk Clutch Lever
Tusk Anodized Clutch Reservoir Cap Tusk High Pressure Radiator Cap Tusk Racing Axle Block
Tusk Anodized Clutch Reservoir Cap Tusk High Pressure Radiator Cap Tusk Racing Axle Block
Tusk Oil Filler Plug Tusk Billet Aluminum Steering Stem Nut Attack Graphics Custom Alloy Complete Bike Graphics Kit
Tusk Oil Filler Plug Tusk Billet Aluminum Steering Stem Nut Attack Graphics Custom Alloy Complete Bike Graphics Kit
Dunlop MX33 Geomax Soft-Intermediate Terrain Tire Tusk Stainless Steel Typhoon Front Brake Rotor Tusk Stainless Steel Typhoon Rear Brake Rotor
Dunlop MX33 Geomax Soft-Intermediate Terrain Tire Tusk Stainless Steel Typhoon Front Brake Rotor Tusk Stainless Steel Typhoon Rear Brake Rotor
Rocky Mountain ATV/MC Grip Donuts Tusk Power Valve Cover
Rocky Mountain ATV/MC Grip Donuts Tusk Power Valve Cover