KTM LAUNCHES A NEW GENERATION OF ENDURO MACHINES

NEW GENERATION EXC / EXC-F / XC-W TPI / XCF-W 2020

Developed on the toughest climbs, gnarliest terrain and in deepest mud with our FMF KTM Factory Racing stars, the benchmark-setting KTM offroad models have just raised the bar yet again. The 2020 lineup includes the new KTM 150 XC-W TPI, KTM 250 XC-W TPI and KTM 300 XC-W TPI 2-strokes, as well as the new offroad-only KTM 350 XCF-W and KTM 500 XCF-W 4-strokes. Rounding out the new models are the KTM 350 EXC-F and KTM 500 EXC-F dual sports.    

Building on the constantly evolving and advancing technology found in KTM’s enduro machines, this wide range of KTM models boasts the very latest in innovation. These 2020 machines feature updated high-performance engines, a new chassis with improved WP XPLOR suspension, improved handling, new bodywork, new air filter box, new cooling system, and new exhaust systems. These improvements and refinements, combined with the high-quality NEKEN handlebar, Brembo brakes, No-Dirt footpegs, and CNC-milled hubs with Giant rims fitted as standard equipment, ensure that the new KTM EXC and XC-W machines are the best performing and most extreme offroad and dual-sport bikes on the market.

To get the very best out of the new KTM EXC and XC-W model lineup, KTM has continued to develop its high-quality selection of KTM PowerParts, which enables riders to customize their machines to take it to new heights. KTM enduro fans can also find a wide range of riding gear, protection and casual wear in the KTM PowerWear collection, ensuring they can be READY TO RACE both on and off the bike.

HIGHLIGHTS 

  • Improved engines with more efficient performance

  • All 2-stroke models fitted with the latest TPI technology

  • Reworked frames with improved stiffness, longer subframe

  • New bodywork with improved ergonomics and better seat comfort

  • Improved radiators/cooling system 

  • Improved suspension settings 

  • Newly designed exhaust systems 

  • New graphics and colors

 MODELS

  • KTM 150 XC-W TPI, a new TPI model

  • KTM 250/300 XC-W TPI

  • KTM 350/500 EXC-F

  • KTM 350/500 XCF-W, new off road-only models


274957_500 XCF-W 2020.jpg

2020 500 XCF-W


280187_500 EXC-F USA 2020.jpg

2020 500 EXC-F

KTM 500 EXC-F/XCF-W INTRODUCTION Stand back or hold on tight, this is the most powerful dual-sport on the market. The new generation KTM 500 EXC-F packs a thrilling 4-stroke punch while still delivering outstanding rideability. A completely reworked chassis and even more compact high-tech engine make this large-displacement powerhouse feel surprisingly light and agile while the reworked WP suspension provides unmatched performance with increased bottoming resistance. As a result, this awesome 510 cc SOHC single cylinder bombshell has an incredible power-to-weight ratio and provides nothing less than the most dynamic dual-sport experience available.

New for 2020, the KTM 500 XCF-W takes everything loved about the KTM 500 EXC-F and strips it down to an offroad-only model with and even harder big-bore punch that still delivers outstanding rideability thanks to industry-leading traction control and selectable maps. Increased power and reduced weight make this nothing less than the most dynamic offroad experience available.

KTM 500 EXC-F/XCF-W ENGINE The 500’s fuel-injected powerhouse features an extremely compact and lightweight design, while delivering awesome torque and power across the rpm range. In the newly developed SOHC cylinder head, the four valves are controlled by extremely rigid rocker arms while flow optimized ports ensure an efficient gas exchange. Vibrations are kept in check by a carefully optimized crank drive with plain bearings, as well as a multifunctional balancer shaft. The cutting-edge Keihin engine management system with electronic fuel injection and a reworked 42 mm throttle body ensure an astonishing response, while a map switch on the XCF-W allows the rider to select a different power curve mid-race and to activate the innovative traction control system for maximized grip.

KTM 500 EXC-F/XCF-W CYLINDER HEAD The engines are fitted with a newly developed SOHC cylinder head which is much more compact, 15 mm lower and 500 g lighter, improving the mass centralization and contributing to even better handling. The gas flow through the newly shaped ports is controlled by a new overhead camshaft which is now closer to the center of gravity, further improving handling. It features a better axial fixation of the de-compressor shaft and a new, more efficient integrated engine breather system. Rocker arms activate four new valves (intake: titanium valves 40 mm, exhaust: steel valves 33 mm) which are shorter and adapted to the new head design. The rocker arms feature an optimized and stiffer design with reduced inertia, guaranteeing more constant performance up to the rpm limit. A shorter chain and new low-friction chain guides contribute to reduced weight and less friction. The new head configuration guarantees a more efficient power delivery and unrivalled performance. 

NEW: 

  • Newly developed SOHC cylinder head àweight reduced by 500 g, 15 mm lower, more compact design, better mass centralization

  • New camshaft with reworked axial fixation of automatic de-compressor shaft and a new centrifugal engine breather àsafer starting, more efficient engine breathing system (less loss of oil)

  • New rocker arms design for improved stiffness, decreased inertia

  • New valves for adapted to new cylinder head configuration

  • Shorter chain, new low-friction chain guide for weight reduction, reduced friction, better reliability

  • New spark plug for more efficient combustion

 

KTM 500 EXC-F/XCF-W CYLINDER AND PISTON The compact cylinder (with 95 mm bore) houses a new, extremely lightweight box-in-box type piston made by König that, in conjunction with a 10% lighter piston pin, delivers major performance and contributes to the engine’s low vibrations and durability. The compression ratio is increased from 11.7 to 12.75:1 for even better engine performance. The piston top land was additionally optimized to ensure a more efficient combustion.

NEW:

  • New box-in-box piston made by König for better performance, improved reliability 

  • Weight reduced piston pin àreduced engine vibrations

 

KTM 500 EXC-F/XCF-W CRANKSHAFT The crankshaft is located close to the center of gravity, contributing to excellent handling. It utilizes a short connecting rod, which contributes to an overall compact and light engine with a snappy power delivery, while balanced inertia supports traction and rideability. A plain big end bearing with two force-fitted bearing shells runs directly on the crank pin. Efficient oil feed to the bearing is ensured by the engine’s pressure lubrication, improving the crankshaft service interval. 

KTM 500 EXC-F/XCF-W COUNTER BALANCE SHAFT The side mounted counter balance shaft, which also drives the water pump, keeps vibrations to a minimum across the rpm range. Thanks to the perfect mass balancing and this powerhouse’s low total oscillating masses, the engine is smooth even while operating at the highest level.  

KTM 500 EXC-F/XCF-W ELECTRIC STARTER Like all KTM 4-stroke motorcycles, the 510cc engine is started with ease by pushing a button, which is an invaluable advantage whether in the heat of battle or while out on the trail.

KTM 500 EXC-F/XCF-W ENGINE CASES & COVERS The new generation engine features reworked engine cases reducing the weight by nearly 300 g. The design features a centralized shaft configuration that makes the engine short and compact and contributes to an efficient mass centralization. The engine covers feature a surface structure which reduces the wear caused by the rider’s boots. In addition, a new reinforced clutch cover makes the engine more resistant to impacts. 

NEW:

  • Reworked engine cases for weight reduction of approximately 300 g

  • Reinforced clutch cover for improved resistance against impacts

500 EXC-F/XCF-W CLUTCH The KTM-developed DDS clutch (damped diaphragm steel) features a wear-free steel basket and extremely heat resistant clutch plates. This design is distinguished by employing a diaphragm spring instead of the usual coil springs, which makes for a considerably easier clutch action. The diaphragm spring also leaves enough space for a damping system integrated into the clutch hub, which benefits both traction and durability.  The hydraulic BREMBO clutch mechanism offers light operation and highly controllable modulation of the clutch.

KTM 500 EXC-F/XCF-W TRANSMISSION The 6-speed transmission ensures the highest durability and reliability level. The gear ratios are perfectly matched to the power delivery of the large displacement engine and have remained the same for 2020.

KTM 500 EXC-F/XCF-W ENGINE MANAGEMENT SYSTEM The state-of-the-art Keihin Engine Management System, with electronic fuel injection, features a new 42 mm throttle body, which provides an instantaneous response and maximum performance thanks to its unique injector position. This guarantees excellent atomization of the fuel with the air on its way to the combustion chamber. In addition, there are separate systems for cold start and idle adjustment. A reworked throttle cable mount allows for smoother routing of the cables and an improved seal of the MAP sensor (MAP = Manifold-Air-Pressure) makes the system even more reliable.

The ECU features a new map adapted to the new exhaust, airbox and engine configuration. On the KTM 500 XCF-W, the ECU regulates the unique traction control which can be activated by the map select switch, which provides two different maps for optimal power characteristics for each gear. 

NEW: 

  • Reworked throttle body àimproved throttle cable routing and better reliability

  • New MAP sensor sealing àimproved reliability

  • XCF-W: New maps, optimized Traction Control set-up àoptimal performance, better traction

  • New injector àimproved reliability

 

KTM 500 EXC-F/XCF-W CONCLUSION

  • Most compact and lightweight SOHC engine design 

  • Robust 6-speed gearbox standard

  • DDS hydraulic clutch, compact design and flawless clutch operation

  • Electric starter for easy and effortless starts

  • Efficient power delivery and class-leading performance


280186_350 EXC-F USA 2020.jpg

2020 350 EXC-F

274955_350 XCF-W 2020 .jpg

2020 350 XCF-W

KTM 350 EXC-F AND XCF-W INTRODUCTION The new generation of the KTM 350 EXC-F takes the successful formula of offering 250-like agility with 450-like power to the next level thanks to a new frame boasting increased straight-line stability, updated WP suspension offering improved performance and increased bottoming resistance and an even more powerful 349.7 cc engine. Significant gains in performance and torque, as well as handling and agility, combined with further refinements to the performance exhaust, optimized cooling system and ergonomic bodywork make the 2020 KTM 350 EXC-F the most dominant dual-sport in its class.  

The all-new KTM 350 XCF-W takes everything riders love about the KTM 350 EXC-F and strips it down to lean and powerful offroad-only model. A reworked engine turns out earth-ripping power and torque—both are kept under control by the industry leading traction control and selectable maps—making the KTM 350 XCF-W ready to dominate the trails. 

KTM 350 EXC-F/XCF-W ENGINE The engine features a compact and very light 61.7 lbs. (28.0 kg) construction. Featuring an improved transmission and a redesigned and lighter DOHC (double overheard camshaft) cylinder head, the engine is stronger and lighter than ever. Lightweight valves and DLC coated finger followers allow for lively but also very durable engine. Fitted with the latest electronic fuel injection system, it has improved performance, and with its electric starter, it boasts incredibly easy operation. 

KTM 350 EXC-F/XCF-W CYLINDER HEAD The reworked cylinder head design features nearly the same proven architecture as before but is now 200 g lighter. New flow-optimized ports and overhead camshafts with optimized timing guarantee outstanding engine characteristics. The finger followers with a DLC coating actuate the lightweight valves (intake 36.3 mm, exhaust 29.1 mm), which allow for high engine speeds. With the new head comes a new cylinder head cover and gasket, a new spark plug and spark plug connector. 


NEW:

  • Reworked cylinder head for reduced weight

  • Reworked ports and cams for improved engine performance

  • New cylinder head cover and gasket, a new spark plug and spark plug connector for adaptations to new head design 


KTM 350 EXC-F/XCF-W CYLINDER & PISTON The new shorter cylinder (with a bore of 88 mm) features a reworked cooling design and is matched to a new, forged bridged box-type piston made by CP. Its piston crown geometry is adapted perfectly to the high-compression combustion chamber while offering an extra rigid structure and low weight. The compression ratio is increased from 12.3 to 13.5:1 for improved engine performance while the low oscillating mass guarantees extremely lively character. 

  • Shorter cylinder for improved engine performance and center of gravity

  • New CP piston with higher CR for improved engine performance across the rpm range 


KTM 350 EXC-F/XCF-W CRANKSHAFT  The 350 engine has a reworked crankshaft which features a new bearing in the small end of the connecting rod while the proven plain big end bearing features two force-fitted bearing shells running directly on the crank pin. This design enhances the engine’s durability, allowing long crankshaft service intervals. 

NEW: Reworked crankshaft with new small-end bearing for improved reliability


KTM 350 EXC-F/XCF-W COUNTER BALANCER SHAFT 
In order to balance the mass-forces, the 350 engine uses a multifunctional counter balance shaft, which at the same time drives the water pump and timing chain. 


KTM 350 EXC-F/XCF-W ELECTRIC STARTER
The 350 EXC-F/XCF-W is fitted with an electric starter as standard, which is a clear advantage when it comes to crunch time in the heat of battle. A strong starter motor made by Mitsuba and the proven starter drive guarantee efficient and reliable starting. 

KTM 350 EXC-F/XCF-W CLUTCH The KTM-developed DDS clutch employs a lightweight diaphragm spring instead of a coil spring system for smoother clutch action. A damping system is integrated into the clutch hub, increasing traction and providing outstanding clutch and transmission durability. Actuated by BREMBO hydraulics, the clutch is distinguished by consistent, precise control across the entire operating temperature range and easy modulation. 

KTM 350 EXC-F/XCF-W TRANSMISSION A new 6-speed transmission made by PANKL features a stronger, forged raw material which ensures the highest level of durability and reliability. The gear ratios, which are perfectly matched to the power characteristics of the engine, have remained the same for 2020.

All four-stroke engines are fitted with a gear sensor giving the option of different engine characteristics for each gear.

NEW:

  • Stronger material for the PANKL transmission for improved durability and reliability

350 EXC-F/XCF-W ENGINE CASES & COVERS A reworked design of the die-cast engine cases has allowed for reduced weight. A centralized shaft configuration makes the engine very short and compact and keeps the mass centralization as efficient as possible, improving handling. A reworked and integrated oil supply improves the lubrication of the main bearing. The engine covers feature a surface structure that reduces the wear caused by the rider’s boots.

NEW: 

  • New engine cases for reduced weight, improved oil supply for main bearing

KTM 350 EXC-F/XCF-W ENGINE MANAGEMENT SYSTEM The state-of-the-art Keihin Engine Management System, with electronic fuel injection, features a new 42 mm throttle body, which provides an instantaneous response and maximum performance thanks to its unique injector position. This guarantees excellent atomization of the fuel with the air on its way to the combustion chamber. In addition, there are separate systems for cold start and idle adjustment. A reworked throttle cable mount allows for smoother routing of the cables and an improved seal of the MAP sensor (MAP = Manifold-Air-Pressure) makes the system even more reliable.

The ECU features a new map adapted to the new exhaust, airbox and engine configuration. On the KTM 350 XCF-W, the ECU regulates the unique traction control which can be activated by the map select switch, which provides two different maps for optimal power characteristics for each gear. 

NEW: 

  • Reworked throttle body for improved throttle cable routing and better reliability

  • New MAP sensor sealing for improved reliability

  • XCF-W: New maps, optimized Traction Control set-up for optimal performance, better traction


274947_150 XC W TPI 2020 .jpg

2020 150 XC-W TPI

KTM 150 XC-W TPI INTRODUCTION “XC” means cross-country. “W” represents its wide-ratio transmission. “KTM” stands for winning. This nimble, lightweight, extreme terrain master is all new for 2020 and now proudly features the “TPI” (transfer port injection) letters next to its name. This means that there is no longer a need for re-jetting or mixing fuel, making this race-ready machine even simpler to ride and work on. Already recognized for its supreme agility, the new KTM 150 XC-W TPI benefits from a brand-new frame with improved flex characteristics that, together with a list of refinements including new bodywork and updated suspension, helps elevate rider and machine to incredible new levels of performance.

150 XC-W TPI ENGINE The engine of the KTM 150 XC-W TPI was developed with the latest know-how and state-of-the-art technology. Thanks to the revolutionary TPI fuel injection and newly developed cylinder, the powerplant produces class-leading power all over the rev range. It’s also the lightest and most compact engine in its class, which is reflected in an unrivalled agility, easy rideability and high performance.  

KTM 150 XC-W TPI CYLINDER Within the heart of the 150 cc engine is a newly developed, compact cylinder. It has a bore of 58 mm and is fitted with a sophisticated power valve unit including a mechanism for the lateral support exhaust ports. For the TPI, the cylinder features newly developed port timings with the upper edge of the exhaust port now precisely CNC machined and two lateral domes holding the fuel injectors that inject fuel into the rear transfer ports. This downstream injection guarantees excellent atomization of the fuel with the upstreaming air for a highly efficient combustion and significantly reduced losses of unburned fuel. This design is the key for outstanding performance over the entire range with significantly increased torque when compared to the predecessor 150 cc carbureted engine.

In conjunction with the new cylinder, the 2-piece cylinder head features an optimized combustion chamber shape for improved combustion. In addition, it now has a water temperature sensor needed for the TPI.

NEW:

  • New cylinder with two additional domes for the injectors, reworked port timing, CNC machined upper edge of the exhaust port àoptimized for TPI implementation, improved bottom-end power, more constant Enduro performance

  • New cylinder head with optimized combustion chamber and an additional water temperature sensor for adaptation to TPI

KTM 150 XC-W TPI ENGINE CASES The lightweight die-cast engine cases feature a high crankshaft position located close to the center of gravity, which results in optimal mass centralization and rideability. In addition, the engine body is extremely compact, contributing to the low engine weight. 

For MY20, a new ignition cover has been adapted to the larger alternator and the reed valve block features reworked carbon reeds for improved reliability. The engine and especially the electric starter motor are now protected by an engine guard made of robust plastic.

NEW:

  • New ignition cover for adaption to new alternator

  • New intake reed design for better reliability

  • New engine guard for protection of the electric starter motor

 

KTM 150 XC-W TPI CLUTCH The KTM 150 XC-W TPI is fitted with a DS (diaphragm steel) clutch featuring a one-piece clutch basket combined with the primary gear made of high-strength billet steel. This compact rivet-less design guarantees unbeatable reliability. The clutch is fitted with extremely heat-resistant steel friction discs which ensure a good disengagement of the clutch. These are pre-tensioned by means of a diaphragm spring, substantially reducing the lever force of the BREMBO hydraulic system.  

KTM 150 XC-W TPI ENGINE MANAGEMENT SYSTEM The MY20 TPI models feature the most modern engine management system (EMS) of any 2-stroke offroad competition motorcycle. The brain of the system is the control unit (ECU) located below the seat. The ECU defines the ignition timing and the amount of fuel to inject utilizing data from various sensors such as intake air pressure, throttle position, water temperature and a new, additional ambient air pressure sensor. This sensor guarantees an immediate adaption of the injection to altitudes changes. Thanks to this automatic altitude and temperature compensation, there is no need to set up the bike for the environment. All you have to do is ride. Should the rider decide to mount an accessory radiator fan from the KTM PowerParts line, it will also be controlled directly by the EMS without adding a thermal switch. An optional map select switch allows the rider to select an alternate map, providing a sportier power delivery, while the standard map is set for smoother and more tractable offroad characteristics.

 KTM 150 XC-W TPI THROTTLE BODY All XC-W TPI engines are fitted with a 39 mm throttle body made by Dell’Orto. Power is controlled by a butterfly valve via a twin-cable handlebar throttle assembly. Airflow data is provided to the engine management by a throttle position sensor. For MY20, the idle system was reworked allowing the idle speed to be set more precisely via the bypass screw. Also, the cold start system is improved for a better supply of extra air when opening the bypass. Oil supplied by the oil tank via an electronically controlled oil pump and intake tube is mixed with the incoming air to lubricate the moving engine parts.

NEW:

  • New throttle body with reworked idle and cold start systems àbetter adjustability of idle speed and cold start enrichment 

 KTM 150 XC-W TPI OIL PUMP The new generation of TPI offroad competition bikes is fitted with a newly designed oil tank featuring reworked fixing points for maximal reliability. The oil pump mounted underneath the oil tank delivers the lubricant to the throttle body, where minute quantities are mixed with the incoming air in order to lubricate the piston and crankshaft. Using engine speed and throttle position sensor data, the engine management’s precise electronic control of the oil pump ensures the perfect amount of oil for any given condition

The filler cap assembly for the oil tank is located between the fuel tank and steering head, utilizing a hose in the upper frame tube to conduct the oil to the storage container. Automatic, electronically controlled oil injection reduces exhaust smoke by up to 50% over conventional pre-mix lubrication, with an average fuel-to-oil ratio of 80:1. This means the oil capacity of about 0.7 liters is sufficient for at least five tanks of fuel.

KTM 150 XC-W TPI TRANSMISSION The KTM 150 XC-W TPI is fitted with a robust 6-speed transmission. The gear ratios are set for Enduro riding and are adapted to the 150 cc power band. The gearbox is made by PANKL, ensuring the quality and reliability are at the highest level.

Instead of a circlip, for MY20, the front sprocket is fixed and secured now with a screw and diaphragm spring, as it is on all other offroad models. This guarantees better reliability.

NEW: 

  • New fixation of the front sprocket  for quality and reliability

KTM 150 XC-W TPI ALTERNATOR In order to accommodate the power requirements of the upgraded engine management system, the TPI models are fitted with a powerful alternator, rated at 196 W, just like on the EXC-F 4-stroke models.

KTM 150 XC-W TPI EXHAUST The KTM 150 XC-W TPI is fitted with a new exhaust system featuring a newly designed exhaust pipe and muffler. The pipe is produced with the latest 3-D stamping technology and has an optimized shape. The reworked design of the silencer, a new perforated silencer core and new, lighter packing wool contribute to the excellent engine performance, with significantly improved bottom-end power over the previous, carbureted model. Last but not least, the plastic mounting system of the muffler is replaced by two welded aluminum brackets, reducing the weight of the muffler. 

NEW:

  • New exhaust pipe àimproved bottom end power, excellent Enduro performance

  • New muffler shape, welded mounting brackets, new core, lighter wool àmore modern look, weight reduction (60 g)

 KTM 150 XC-W TPI FEATURES

  • 250 cc 4-stroke rivalling performance, low maintenance costs

  • 125 agility and handling

  • State-of-the art TPI fuel injection and electronically controlled lubrication

  • Hydraulic clutch and high-end BREMBO brakes

  • Never-ending fun


274952_300 XC W TPI 2020.jpg

2020 300 XC-W TPI

274949_250+XC+W+TPI+2020.jpg

2020 250 XC-W TPI

KTM 250/300 XC-W TPI INTRODUCTION Combining top performance and outstanding rideability, the new generation of KTM 250 and 300 XC-W TPI machines are distinguished by the lowest weight in their class, intuitive handling and a unique style—along with the awesome READY TO RACE performance. The ultimate combination of power and rideability, they have been completely reworked for 2020, featuring a new frame with optimized flex characteristics, a new innovative HD, Heavy Duty, 3D stamped exhaust offering improved impact resistance and reduced noise levels and updated premium WP suspension for unmatched performance in extreme terrain. Setting a clear benchmark thanks to the innovative TPI (transfer port injection) system, these updated models clearly demonstrate KTM’s unrelenting commitment to 2-stroke development. Excellent fuel efficiency, clean exhaust emissions and the benefit of not having to play with jetting out on the trail make TPI technology a rider favorite, and with new mapping and an additional ambient air pressure sensor to improve altitude compensation, the updated KTM 250 and 300 XC-W TPI rippers continue to reach new heights in offroad competition. 

KTM 250/300 XC-W TPI ENGINE The 250 cc and 300 cc 2-stroke machines have been known and respected for offering the most powerful 2-stroke performance in their segments. Thanks to state-of-the-art 2-stroke engine design and technology, with revolutionary TPI fuel injection, and with several improvements for MY20, these powerplants are even more refined than ever. The compact and lightweight 2-strokes are a great choice for advanced Enduro riders searching for easy to ride Enduro performance who are also conscious of their purchasing and maintenance budgets.

KTM 250/300 XC-W TPI CYLINDER & CYLINDER HEAD The 250/300 cc cylinders are fitted with the sophisticated TVC exhaust control and have a bore diameter of 66.4 and 72.0 mm respectively. For the fuel injection system, they feature two lateral domes holding the fuel injectors that inject fuel into the rear transfer ports. This downstream injection guarantees excellent atomization of the fuel with the upstreaming air for a highly efficient combustion and significantly reduced losses of unburned fuel. As of MY20, the cylinders have a fully machined exhaust port window which guarantees more precise timing, while a reworked power valve drive mechanism and adjuster make for more precise adjustment and better function of the power valve. The 250 cc engine has a new cylinder head with a slightly decreased compression chamber volume (-1 cc) for more efficient Enduro performance. Last but not least, the new heads allow the use of a standard (and more commonly used, as it was mounted on the carburetor models) spark plug. 

NEW: CNC-machined exhaust port window àmore precise port timing and constant performance. Reworked power valve mechanism and adjuster for easier adjustment of power valve. New spark plug for more common product, easier availability on the market. New 250 cc cylinder head with reworked compression rate for more efficient Enduro engine characteristics

KTM 250/300 XC-W TPI ENGINE MANAGEMENT SYSTEM The MY20 TPI models feature the most modern engine management system (EMS) of any 2-stroke offroad competition motorcycle. The brain of the system is the control unit (ECU) located below the seat, which features new maps, guaranteeing optimal power delivery and engine performance. The ECU defines the ignition timing and the amount of fuel to inject utilizing various sensor data such as intake air pressure, throttle position, water temperature and a new, additional ambient air pressure sensor. This sensor guarantees an immediate adaption of the injection to altitudes changes. Thanks to this automatic altitude and temperature compensation, there is no need to set up the bike for the environment. Should the rider decide to mount an accessory radiator fan from the KTM PowerParts line, it will also be controlled directly by the EMS without adding a thermal switch. An optional map select switch allows the rider to select an alternate map, providing a stronger and sportier power delivery.

NEW: Additional ambient pressure sensor for better fuel adjustment for fast altitude changes. Reworked engine maps for optimal power delivery and engine performance.

KTM 250/300 XC-W TPI THROTTLE BODYAll TPI engines are fitted with a 39 mm throttle body made by Dell’Orto. Power is controlled by a butterfly valve via a twin-cable handlebar throttle assembly. Airflow data is provided to the engine management by a throttle position sensor. For MY20 the idle system was reworked allowing the idle speed to be set more precisely via the bypass screw. Also, the cold start system is improved for a better supply of extra air when opening a bypass. Oil supplied by the electronically controlled oil pump via an oil intake tube is mixed with the incoming air to lubricate the moving engine parts.

NEW: New throttle body with reworked idle and cold start systems for better function and adjustability of idle speed and cold start enrichment 

KTM 250/300 XC-W TPI OIL PUMP The new generation of TPI offroad competition bikes is fitted with a newly designed oil tank featuring reworked, more flexible mounting, guaranteeing maximal reliability. In addition, the oil exit is protected by a mesh filter in order to avoid any dirt getting to the oil pump. The oil pump is mounted underneath the oil tank and delivers the lubricant to the throttle body, where minute quantities are mixed with the incoming air in order to lubricate piston and crankshaft. Using engine speed and throttle position sensor data, the engine management’s precise electronic control of the oil pump ensures the perfect amount of oil for any given condition.

The filler cap assembly for the oil tank is located between the fuel tank and steering head, utilizing a hose in the upper frame tube to conduct the oil to the storage container. Automatic, electronically controlled oil injection reduces exhaust smoke by up to 50% over conventional pre-mix lubrication, with an average fuel-to-oil ratio of 80:1. This means the oil capacity of about 0.7 liters is sufficient for at least five tanks of fuel.

NEW: Reworked oil tank design with elastic mounts for improved reliability. Additional mesh filter in the oil exit for reduced risk of clogging the oil pump with dirt.

KTM 250/300 XC-W TPI BALANCER SHAFT For optimal mass centralization, the lightweight, die-cast crankcases hold the clutch shaft and the crankshaft in a high position close to the center of gravity, offering improved handling. In addition, this design allows the implementation of a lateral balancer shaft to minimize vibrations, enhancing comfort and reducing rider fatigue during long and demanding rides and Enduro events and rallies.

KTM 250/300 XC-W TPI CLUTCH The 250 and 300 cc models employ the KTM-developed DDS clutch (damped diaphragm steel) with a highly resilient steel basket and extremely heat resistant clutch plates, a design distinguished by a considerably easier clutch operation than with conventional coil springs. The diaphragm spring also leaves sufficient space for a damping system integrated into the clutch hub, which benefits both traction and durability.

The hydraulic BREMBO clutch mechanism is synonymous with a light action and highly controlled clutch modulation.

KTM 250/300 XC-W TPI ALTERNATOR
In order to accommodate the power requirements of the upgraded engine management system, the TPI models are fitted with a powerful alternator, rated at 196 W, just like on the EXC-F 4-stroke models, as well as the EXC-F voltage regulator.

KTM 250/300 XC-W TPI TRANSMISSION A new 6-speed transmission made by PANKL RACING SYSTEMS is made of a new and stronger, forged raw material which ensures the highest durability and reliability levels. The gear ratios are perfectly matched to the power characteristics of the engine and remained the same for 2020. 

NEW: Stronger material for all gears made by PANKL for improved durability and reliability

KTM 250/300 XC-W TPI WATER PUMP The engine features a reworked water pump casing in order to optimize the flow of coolant for more efficient cooling. 

NEW: Reworked water pump for more efficient cooling

 KTM 250/300 XC-W TPI FEATURES

  • Unbeatable power-to-weight ratio

  • Low weight and excellent agility 

  • State-of-the-art TPI electronic fuel injection

  • Electronically regulated oil pump

  • DDS hydraulic clutch system for effortless and flawless clutch action


    Go to https://www.ktm.com/us/ for more information

 

Chris Glaspell

The success of any online publication depends on the quality of execution, and
in this respect UpShift Online’s success is virtually assured.  It was founded by veteran motorcycle industry professionals: English-born photographer Simon Cudby, the premier photographer in the world of motocross, and Chris Glaspell, creative director with firms serving clients that include Suzuki, Yamaha, Kawasaki, Cycle World and Yoshimura. This, plus Upshift’s veteran editorial staff and unrivaled journalism, will gives readers unparalleled views of adventure motorcycling.