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🔋 Vanon Batteries — 12% OFF with code BOONIE: https://www.vanonbatteries.com/discou... In this one we’re in the shop giving Lucas’s KTM 150 SX a full refresh before he heads to Moto Academy. The bike runs fine, but with around 60 hours on the top end and mystery suspension history, it’s time to go through everything and make sure it’s as safe and solid as we can get it. I pull the forks and shock so they can be rebuilt, tear the top end off, check the crank and flywheel for play, and fight with the power valve linkage without dropping tiny circlips into the engine. Along the way I lean on “YouTube University,” some advice from an old-school vintage racer, and a lot of dad-determination to get this bike right for Lucas. Later in the video we’re back in the shop with fresh parts, walking through ring orientation, installing the piston in the cylinder, setting the base gasket, and dropping the cylinder back on. Lucas jumps in on camera duty and cleaning duty while we button the KTM up and get it ready for its next chapter. If you’re into dirt bikes, two-strokes, or just hanging out in the shop while a dad and son wrench on a KTM, you’ll feel right at home here. In this video you’ll see: Checking crank and flywheel play on a KTM 150 SX Safely removing power valve linkages and tiny circlips Pulling the cylinder, inspecting a worn piston, and planning machine work Simple tips to avoid dropping parts into the engine Ring orientation and piston install tricks on a two-stroke Reassembly, cleaning, and final walk-around of Lucas’s rebuilt bike 👍 Like & subscribe for more dirt bike and shop content. Drop a comment if you’ve rebuilt a two-stroke top end at home or have any tips for keeping kids safe while they learn motocross. #booniesgarage #ktm150sx #father&sonrebuild Affiliate links: 🔵 vidIQ (I use this for every upload): https://vidiq.com/BarrettD 🔋 Vanon Batteries — 12% OFF with code BOONIE: https://www.vanonbatteries.com/discou... 💬 Join our Discord community: / discord 🏠 Our website: https://www.booniesgarage.com/ ✂️ OpusClip (AI auto-clipping): https://www.opus.pro/?via=22935f Chapters 00:00 – Shop Day: Lucas’s KTM 150 SX Tear-Down Plan 01:14 – Why the Top End & Suspension Need Attention 03:30 – Draining Coolant & Stripping the Bike Down 06:36 – Checking Flywheel & Crankshaft Play (Crank Health Check) 08:13 – Power Valve Cover Off & Finding the Hidden Linkage 14:13 – YouTube University: How to Remove That Tiny Circlip Safely 18:19 – Cylinder Off & First Look Inside the Engine 20:06 – Pulling the Piston, Wrist Pin & Clips Without Losing Parts 23:39 – Worn Piston Inspection & Game Plan for Cylinder Work 24:18 – Suspension Tear-Down Begins (Forks & Shock Coming Off) 26:41 – Fighting Seized Hardware & Keeping the Chassis Stable 29:47 – Bike on Stands: Rolling Chassis Ready for Rebuild 30:33 – Rebuild Night: Fresh Top End Going Back On 32:22 – Ring Orientation, “IN” Markings & Google Troubleshooting 35:30 – Sliding the Piston into the Cylinder (Dad & Son Tag Team) 38:08 – Dropping the Cylinder & Protecting the Crank from Dropped Clips 41:01 – Base Gasket, Wrist Pin & Final Circlip Wrestling 44:54 – Torquing the Cylinder & Lucas on Cleaning Duty 50:48 – Camera Died… But the KTM Is Fully Rebuilt 51:40 – Final Walk-Around, Moto Academy Plans & Sign-Off