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2015 KTM OFF-ROAD LINEUP

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2015 KTM 250 XC-W
XC-W & EXC MY 2015
Highlight features:
•      New MAE digital speedometer
•      New black anodized Neken handlebar
•      New Dunlop GEOMAX AT81 tires on XC-W’s
•      New Metzler Six Day DOT tires on EXC’s
•      Improved hand guards with new material
•      New softer compound grips
•      Updated PDS on the 200 XC-W
•      New black colored rims from Giant
•      Orange colored frame
•      New colors and graphics

Benefits:
•      More readily visible information from the speedometer, in a more modern design
•      The hand guards have improved impact resistance
•      Increased grip comfort for less rider fatigue thanks to the softer grips
•      Full range of two-stroke and four-stroke models
•      Electric starter is standard equipment on all models
•      Class-leading performance is maintained for yet another year


2015 KTM 350XCF-W

Frame
The XC-W / EXC chassis is second to none and for 2015 the bikes will feature the striking KTM Factory orange usually seen only on KTM’s race team machines. The modern and lightweight frame design with exceptional quality and performance developed by KTM and produced by WP Performance Systems is made of lightweight, high-strength chromoly steel sections. Not only does it guarantee easy handling and precise cornering, but also outstanding stability.

Suspension
The XC-W / EXC models feature WP suspension, which is specifically designed for Enduro racing and ensures maximum traction comprised with plenty of comfort. As expected, the compression and rebound damping can be adjusted to suit racing conditions and rider preference as well as separate high and low speed shock compression adjustments. For MY 2015, the PDS monoshock tuning has been revised on some two-stroke models and features an improved seal for a more simplified seal change.

Speedometer
A new MAE speedometer has been included on the MY 2015’s with a clean, minimalistic and integrated design. This includes the warning and indicator lights in a tidy, single unit with clear and more readily available information.

Airbox
The XC-W / EXC airbox offers maximum protection of the air filter against dirt in the toughest of terrains whilst ensuring maximum airflow for top performance. The airbox covers are produced to the highest quality in a two-component process, with new in-mold graphics, and for ease of use the filter can be changed without using tools for fast and efficient maintenance. There are also two extra mounting points on the cover that allow it to be secured with bolts if desired.

Wheels
The XC-W’s feature new high-quality black anodized Giant rims with black spokes, that are mated to CNC-machined hubs and lightweight silver aluminum nipples for maximum stability at minimum weight. The XC-W’s feature new Dunlop GEOMAX AT81 tires.

The EXC’s feature the same components but with silver anodized Giant DOT rims. These high-quality, lightweight rims have been developed for KTM and offer top performance and feature Metlzer Six Day DOT tires.

Brakes
High-Tech Brembo brakes have always been standard equipment on KTM’s off-road range, and combined with the lightweight Galfer Wave discs, they are the ultimate solution in braking technology; with their class-leading brake performance, they remain unchanged for MY 2015.

Swing arm
To improve on weight-saving as well as optimal stiffness, the benefits from refinements to the swing arm using the latest in calculation and simulation software. These design changes are reflected in the wall thickness of the cast aluminum swing arm, which shaves off even more weight along with a precisely defined flexibility.

Triple clamps
The triple clamps have been specifically designed for Enduro use and ensure precise handling on rough terrain by supporting the flex characteristics of the fork. This gives the rider the best possible feedback from the front-end of the machine to increase his or her confidence and overall speed.

Handlebars
All XC-W and EXC models are fitted with the super strong, tapered black colored Neken handlebars made of high tensile strength aluminum alloy. The proven standard KTM mount offers four handlebar positions so the fit can be perfected for any rider, and the hand guards fitted to this range are manufactured using a new material for better impact resistance and protection.

Graphics
As with each new year, we bring you a brand new “Ready To Race” graphic design to complete the look of the Enduro bike range.

Bodywork
To improve rider feeling and to create harmony between rider and bike the new bodywork shape incorporates a minimalist design for a more ergonomic feel.

Fuel tank
Refueling is always important during enduro races for those who want the smoothest of refuels during competition and a long range on their machines. All of the fuel tanks are made of lightweight translucent material and have a release mechanism on the ¼ turn bayonet filler cap that can be opened quickly and easily.

Exhaust system
Light and tough, the aluminum silencers are known for their outstanding performance while ensuring low noise levels. Spark arresters are standard on the four-stroke models.

Cooling system
KTMs proven integrated cooling system routes the coolant from the cylinder head through the frame triangle directly to the aluminum radiators made by WP.

Electrics
(NEW)

The XC-W and EXC boasts an efficient wire harness with an advanced ECU, which boasts lightweight connectors and fuse mounts that save weight and keep the electrical system simplified. The 200, 250 and 300 XC-W models have a new, lighter 3Ah battery, which also contributes to the overall weight saving of the machine.

FOUR-STROKE MODELS

250 XCF-W

The smallest of the KTM four-stroke range, which is liked for its strong engine combined with its agile, flickable chassis characteristics, has delivered another world title in the hands of Antoine Meo in 2013. The compact and powerful engine, along with the very maneuverable chassis, remain unchanged for MY 2015.

The basis of this machine shares many components with the successful 350 XCF-W engine, and enjoys class leading performance with plenty of torque thanks to the dynamic power delivery, along with an advanced fuel injection system. The bike is agile and controllable for complete rider confidence, with state of the art technology for good throttle response and power delivery. The DDS clutch system with Brembo hydraulics offer a flawless clutch operation while the electric and kick starter guarantee trouble-free starting in any situation.

Cylinder head

The centerpiece of the KTM XCF-W DOHC (Double overhead camshaft) engine is the cylinder head with two overhead camshafts and DLC coated followers, which are ultra-lightweight. The large, flow optimized ports in combination with large intake valves offer a perfected flow rate to deliver significant performance. The camshafts have been designed to achieve maximum power and torque, while maintaining a power delivery suited to enduro riding. The engine boasts lightweight titanium valves and followers for low oscillating masses along with high rpm.

Cylinder/piston

The 250 short stroke and large bore allows for the use of large intake valves and this, combined with the forged bridged-box style piston, guarantees optimum performance and a dynamic power delivery thanks to its low oscillating mass and large diameter.

Valve train

The crankshaft drives an intermediate shaft on the side, which drives the integrated coolant pump and the two camshafts via the cam chain, while also acting as a counter balancer. This design is compact and efficient, which offers reduced vibration throughout the machine. A hydraulic chain tensioner ensures guaranteed chain tension to achieve highly precise valve timings.

Oil pump
(NEW)

For MY 2015, the oil pump suction screen has new O-rings that increase durability under extreme conditions and over time.

Crankshaft

The 250 XCF-W’s crankshaft has a flywheel that is designed to achieve optimum traction. The crankshaft itself employs a plain big end bearing, while two force-fitted bearing shells run directly on the crank pin. The necessary oil feed for this bearing is delivered by the engine’s pressure lubrication. This design increases the engine’s long-term durability, lengthening crankshaft service intervals, which is a customer benefit

Crankcase

The pressure die cast crankcase has been designed with a significantly reduced wall thickness compared to those cases produced by gravity die cast. The aluminum alloy used has a high tensile strength, while ensuring a high resilience against stone-chipping and other damage.

Starter

The 250 XCF-W engine has the benefit of having an electric starter and a kick starter. Situated behind the cylinder for good protection, the electric starter is connected to the starter freewheel on the ignition rotor via the starter drive in the ignition cover.

DDS Clutch
(NEW)

The 250 XCF-W has a DDS (damped diaphragm steel) design with a wear-free clutch basket, which has been revised for MY 2015 for weight saving, and operates with a diaphragm spring. The basket is machined from high-tensile steel in one piece together with the primary drive gear. This process guarantees unbeatable reliability and contributes to the narrow engine width thanks to its compact rivet-less design, as well as thin steel linings that assist with the compact clutch dimensions. The diaphragm spring makes it possible to implement an additional rubber damping system inside the clutch hub that offers reliability for the transmission and good traction. This, combined with the hydraulic clutch mechanism by Brembo, presents a very light operation and good controllable modulation of the clutch.

Transmission
(NEW)

Specially developed for the 250, the six-speed enduro gearbox has comparatively short gear ratios in fourth and fifth, as well as a new longer overdrive sixth gear. The transmission is renowned for its easy and precise shifting.

Engine Management System (EMS)

The Engine Management System by Keihin with electronic fuel injection and a 42mm throttle body ensures a spontaneous response and maximum engine performance. An oil-cooled 196W AC alternator provides sufficient energy for the fuel injection, lighting and other electrical loads, while the efficient ECU offers fast and reliable data processing.

350 XCF-W & EXC-F

Introduction
The 350 XCF-W is the ultimate enduro machine thanks to its compact, powerful DOHC (Double overhead camshaft) engine, its low weight, along with its perfectly tuned suspension, this machine masters each and every challenging type of terrain. With its playful handling it always holds the advantage when the going gets tough. The 350 EXC-F has all the same benefits of the XCF-W offroad motorcycle with the necessary components to make it street-legal for racing transfer sections and all day dual sport riding.

Engine

The 350cc four-stroke engine with a state-of-the-art electronic fuel injection system offers a wide power band and is distinguished by a dynamic yet fatigue-proof power delivery. At over 45hp of maximum power, the 350 is strong enough to compete with any 450.

Cylinder Head

The DOHC cylinder head contains four ultra-lightweight titanium valves (intake 36.3mm, exhaust 29.1mm), which allow for extremely high engine speed levels of up to 12,000rpm in combination with very small DLC coated followers that weigh only eight grams. The camshaft timings are perfectly tuned for performance in the Enduro specific low rev range.

Valve train

The crankshaft drives an intermediate shaft on the side, which in turn drives the coolant pump and the two camshafts via the cam chain, while at the same time acting as a counter balancer. A hydraulic chain tensioner ensures reliable chain tension to achieve highly precise valve timings.

Crankshaft

Compared to the 350 SX-F, the 350 XCF-W/ EXC-F has a heavier crankshaft in order to achieve a more even power delivery and better traction through the greater gyrating mass. The crankshaft employs a plain big end bearing. Two force-fitted bearing shells run directly on the crank pin. The necessary oil feed for this bearing is delivered by the engine’s pressure lubrication. This design increases the engine’s long-term durability, lengthening crankshaft service intervals – a customer benefit in terms of time, effort and cost.

Crankcase

The pressure die-cast crankcase has been designed with significantly reduced wall thicknesses compared to cases produced by gravity die-casting. The aluminum alloy utilized has great tensile strength while ensuring high resilience against stone-chipping and other damage.

Starter

The engine is equipped with a kick starter as well as an electric starter. Well protected behind the cylinder, the electric starter is connected to the starter freewheel on the ignition rotor via the starter drive in the ignition cover.

DDS Clutch
(NEW)

The single-piece basket of the DDS clutch (damped diaphragm steel) is machined from solid high-tensile steel in one piece together with the primary drive gear. This process guarantees unbeatable reliability and contributes to the narrow engine width due to its compact rivet-less design. This construction also allows the use of thin steel linings that contribute to the compact clutch dimensions. The diaphragm spring makes it possible to implement an additional rubber damping system inside the clutch hub, which offers the certainty of reliability for the transmission and good traction. For MY 2015, the clutch basket has been reworked, making it lighter. To compliment the diaphragm spring the Brembo hydraulic clutch mechanism offers a very light operation and good, controllable modulation of the clutch.

Transmission
A six-speed gearbox with precise shifting compliments the 350 XCF-W/ EXC-F. The six-speed gearbox is specifically matched to the power delivery of the 350cc engine and any kind of enduro and dual sport activity. It offers easy and precise shifting.

Generator

The 350 engine is equipped with a 196W generator with integrated starter freewheel. The generator provides sufficient energy for the fuel injection, lighting and other electrical loads. Compared to the 350 SX-F, the oil-cooled rotor has a bigger diameter with a larger flywheel mass and requires a larger ignition cover.

Oil circuit
(NEW)

The 350 engine is equipped with two oil pumps. A pressure pump provides reliable lubrication for the crankshaft, piston, counter balance shaft and valve train, while cooling the ignition and lubricating the clutch. A scavenger pump draws oil from the crankcase to lubricate the transmission. This also creates a small vacuum within the crankcase, which increases engine performance. For MY 2015, the oil pump suction screen has new O-rings that increase durability under extreme conditions and over time.

Engine Management System (EMS)

The Engine Management System by Keihin with electronic fuel injection and a 42mm throttle body ensures a spontaneous response and maximum engine performance.

400 XC-W & 500 XC-W/ EXC

The 450 and 500 XC-W models are undisputedly the most powerful enduro machines of their classes. Combining low weight and high displacement, the high-tech SOHC (Single Overhead Cam) four-stroke technology is the right choice for all of those who are looking for maximum four-stroke performance combined with playful handling. These powerhouses are without a doubt the benchmarks in their respective classes. The 500 EXC is the absolute leader in high performance dual sport riding. The 500 retains all the legendary offroad capabilities of the XC-W and adds the street-legal components for maximum versatility and go anywhere performance.

Engine

Developed for tough Enduro duties, the SOHC engines with 449.3 and 510.4cc displacement are distinguished by an extremely compact design, easy maintenance and excellent durability at a minimal weight. Together with the Keihin EFI system, these engines provide unrivaled enduro specific performance and rideability.

Cylinder head

The cylinder head is equipped with a single overhead camshaft. It activates two titanium intake valves and two steel exhaust valves. The weight optimized valve train leads to low friction for improved performance as well as low engine braking action.

Piston

The lightweight, forged bridged box-type piston shares its high performance piston rings with the 450 SX-F.

Counter balancer

In order to balance the mass-forces, the engine uses a compact counter balance shaft, which doubles up as a water pump drive.

Crankshaft

The crankshafts with strokes of 63.4mm (450 XC-W) and 72.0mm (500 XC-W/EXC) with ultra-lightweight conrods are made by Pankl from special high-tensile strength steel. The crankshaft employs a plain big end bearing. Two force-fitted bearing shells run directly on the crank pin. The necessary oil feed for this bearing is delivered by the engine’s pressure lubrication. This design increases the engine’s long-term durability, lengthening crankshaft service intervals, which is a customer benefit in terms of time, effort and cost.

Starter

Both bikes are equipped with kick starts as well as electric starters as standard. The electric starter is well protected behind the cylinder.

DDS clutch

The single-piece basket of the DDS clutch (damped diaphragm steel) is machined from solid high-tensile steel in one piece together with the primary drive gear. This process guarantees unbeatable reliability and contributes to the narrow engine width due to its compact rivet-less design. This construction also allows the use of thin steel linings that contribute to the compact clutch dimensions. The diaphragm spring makes it possible to implement an additional rubber damping system inside the clutch hub, which offers the certainty of reliability for the transmission and good traction. For MY 2015, the clutch basket has been reworked, making it lighter. To compliment the diaphragm spring the Brembo hydraulic clutch mechanism offers a very light operation and good, controllable modulation of the clutch.

Transmission

The proven wide-ratio six-speed gearbox is distinguished by easy and precise shifting.

Oil circuit

The engine features two oil pumps and a common oil circuit. A pressure pump provides reliable lubrication for the crankshaft, piston, counter balance shaft and valve train, while cooling the ignition and lubricating the clutch. A scavenger pump draws oil from the crankcase to lubricate the transmission. For MY 2015 the oil pump suction screen has new O-rings that increase durability under extreme conditions and over time.

Engine Management System (EMS)

The Engine Management System by Keihin with electronic fuel injection and a 42mm throttle body delivers a spontaneous response and maximum engine performance.  An oil-cooled 196W AC alternator provides sufficient energy for the fuel injection, lighting and other electrical loads.

TWO-STROKE MODELS

200 XC-W
The 200 XC-W is the perfect combination of a 125’s playful handling with impressive engine power that’s very close to the feeling of a 250. The 200 XC-W is equipped with an electric starter for easy and reliable engine starting. Combined with its superb rideability, the 200 XC-W is user-friendly and fun. This makes it the first choice for riders who are looking for perfect handling, first-rate comfort and plenty of power outside of the competitive class society as well as those who rate fun, easy riding combined with reasonable maintenance costs.

Benefits:
•      NEW – a new rear shock with mono-seal joint ring for an improved seal and simplified seal change
•      NEW – carburetor setting for a better, smoother power delivery
•      NEW – 3Ah battery, which is lighter and efficient
•      Impressive power in a compact and light chassis
•      Amazing riding pleasure
•      Electric and kick starter for trouble-free, easy starting in any situation
250 XC-W
An unbeatable power-to-weight ratio, low purchase and ownership costs makes the 250 the primary choice for extremely heavy enduro duty. The cutting-edge engine is started effortlessly via an electric starter and has been considered the most successful two-stroke power plant on the market. Best-in-class enduro performance combined with a perfectly geared six-speed transmission and a DDS clutch make this engine the absolute top dog in its segment.

Benefits:
•      NEW – power valve setting with opening point at +200rpm compared to the previous setting for a smoother power delivery
•      NEW – CDI curve optimized for new power valve setting
•      NEW – ignition cover with new gasket for improved sealing
•      NEW – gasket on inner clutch cover for improved sealing
•      NEW – carburetor setting for a better, smoother power delivery
•      NEW – 3Ah battery, which is lighter and guarantees efficient starting
•      NEW – shorter gearing on electric starter for higher initial torque and better starting
•      Unbeatable power-to-weight ratio
•      The pinnacle of two-stroke technology
•      Electric and kick starter for trouble-free, easy starting in any situation

300 XC-W
The 300 XC-W has clearly proven its capabilities in many off-road competitions. The combination of massive two-stroke performance, a huge amount of torque and an incredibly agile chassis make it the first choice when the going gets really difficult. There is no better power-to-weight ratio in a standard bike available. The compact two-stroke engine offers the strongest performance money can buy. A perfectly tuned exhaust control ensures that the power delivery is manageable, while the six-speed gearbox, which has been specifically geared for enduro duty, has always the right gear ratio on offer.

Benefits:
•      NEW – ignition cover with new gasket for improved sealing
•      NEW – gasket on inner clutch cover for improved sealing
•      NEW – carburetor setting for a better, smoother power delivery
•      NEW – 3Ah battery, which is lighter and guarantees efficient starting
•      NEW – shorter gearing on electric starter for higher initial torque and better starting
•      Extreme enduro performance
•      Low running costs compared to equivalent 4-strokes
•      Electric and kick starter for trouble-free, easy starting in any situation

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