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TSP TPI Power Kit Instructions

These are additional instructions and information regarding installing our TPI Power kit to your bike.
Please see the following link for Initial setup procedure & liability PDF that was provided to you with your invoice. This will include spark plug type, air & idle screw settings, and some other useful information for your TSP Power kit: TPI Power Kit Customer Notes and Release of Liability v4

 

Head & Insert Specification and Squish clearances:

KTM/Husky 250cc Carby & TPI Billet Head 2008-2016 & 2017-on – LOW/MID/HIGH/V-HIGH COMP:

Installation instructions (New one piece style head + changeable insert):

  • Drain coolant and remove existing head
  • Set deck height using different base gaskets as necessary. Deck height is the distance between the top of the cylinder and the top of the outer piston edge at Top Dead Centre (TDC).
  • Install new head O rings on top of the cylinder and make sure dowel pins are in place and properly seated.
  • Place the supplied 23×2.5mm o-ring into the groove on top of the combustion chamber insert. Place the outer ‘Cap’ section of the head over the insert, taking care not to dislodge the o-ring. Screw the spark plug finger tight into the top of the insert. Holding the spark plug, lift the head assembly onto the cylinder as one unit. Position the head carefully, making sure dowel pins align and o-rings remain seated.
  • Tighten nuts/bolts in a criss-cross pattern to the required torque spec in your owners manual. Refit the head to chassis mount brackets.
  • For Carby models install the optional Coolant Plug into the 10mm threaded hole at the rear of the head. For TPI models install the temperature sensor into the 10mm threaded hole.

KTM/Husky 300cc Carby & TPI Billet Head 2008-2016 & 2017-on – LOW/MID/HIGH/V-HIGH COMP:

Installation instructions (New one piece style head + changeable insert):

  • Drain coolant and remove existing head
  • Set deck height using different base gaskets as necessary. Deck height is the distance between the top of the cylinder and the top of the outer piston edge at Top Dead Centre (TDC).
  • Install new head O rings on top of the cylinder and make sure dowel pins are in place and properly seated.
  • Place the supplied 23×2.5mm o-ring into the groove on top of the combustion chamber insert. Place the outer ‘Cap’ section of the head over the insert, taking care not to dislodge the o-ring. Screw the spark plug finger tight into the top of the insert. Holding the spark plug, lift the head assembly onto the cylinder as one unit. Position the head carefully, making sure dowel pins align and o-rings remain seated.
  • Tighten nuts/bolts in a criss-cross pattern to the required torque spec in your owners manual. Refit the head to chassis mount brackets.
  • For Carby models install the optional Coolant Plug into the 10mm threaded hole at the rear of the head. For TPI models install the temperature sensor into the 10mm threaded hole.

KTM/Husky 150cc Insert 16-on – MID/HIGH COMP:

Installation instructions:

  • Remove existing head
  • Check deck height (distance from the top of the cylinder to the top of the piston edge at Top Dead Centre). Adjust by installing different base gaskets if necessary. Your new Billet head is designed to work with the factory installed base gasket thickness.
  • Install new head O rings
  • Make sure dowel pins are in place and properly seated
  • Install your Billet Head making sure that the 2 inner O rings that seal between the 2 parts are properly in place and do not get pinched. If necessary coat them in oil to help avoid pinching.
  • Tighten head nuts/bolts in a criss-cross pattern to the required torque spec in your owners manual.

TPI Idle bolt Video Installation: