KTM has released information on its 2019 off-road two-stroke line, starting with the XC-W models. The flagship of these is the 300XC-W TPI, which is now fuel-injected. For the XC line, click the image below. The official press release for the XC-W line follows below that.
KTM has a long tradition making high-end offroad competition motorcycles. While the KTM 150 XC-W is equipped with a traditional carburetor, the 250 and 300 cc XC-W TPI models are now both fitted with the revolutionary TPI serial fuel injection and have set new standards in the 2-stroke offroad segment. TPI stands for “transfer port injection”; a global-first, groundbreaking technology for 2-stroke racing engines that delivers a previously unattainable combination of top performance and outstanding ride ability. No more jetting combined with a massive reduction of fuel consumption while the lubrication is taken care by an electronically controlled oil pump instead of using premix.
The frames of all KTM off-road models are manufactured from lightweight sections of top-quality chrome-molybdenum steel tubing of various cross sections. This type of frame design provides high torsional rigidity for best handling and ride ability, while a certain longitudinal flexibility can absorb the wheel impact energy, supporting the suspension for reduced rider fatigue. At the same time, the frame triangle serves to deliver the coolant from the cylinder head directly to the radiators. In the TPI models, the frame design also serves to route engine oil from a filler cap assembly, located between the fuel tank and the steering head, via a hose inside the upper frame tube to the oil tank.
This swing arm design allows for an optimal mounting position of the PDS (progressive damping system) rear shock ensuring a high progression rate. The single-component casting process eliminates any inconsistencies and weak points that would be inherent in a welded swing arm.
All XC-W models are fitted with the latest WP XPlor 48 upside-down forks, a split fork design developed by WP Performance Systems and KTM. It is fitted with springs on both sides but separate damping functions. Compression damping is on the left and the rebound on the right hand side without influencing each other. Therefore damping can easily be adjusted via the dials on top of both fork tubes with a range of 30 clicks each.
Already distinguished by outstanding response and damping characteristics the fork features an updated slightly stiffer setting for model year 2019 keeping the front end higher and providing increased reserves against bottoming out.
Updated, slightly stiffer fork setting improved feedback and more bottoming resistance
Fitted to all XC-W models, the WP XPlor PDS shock absorber is the key element of the proven and successful PDS rear suspension design (Progressive Damping System) where the shock is directly linked to the swing arm without an additional linkage system. Optimal damping progression for offroad duty is achieved by a second damping piston in combination with a closed cup towards the end of the stroke, and supported by a progressive shock spring. This means the XPlor PDS shock provides excellent damping performance and a high resistance against bottoming out. An updated main piston and new settings provide improved damping characteristics and match perfectly the reworked front end set-up. Fully adjustable including high- and low speed compression you can set the shock to any track and riders preferences.
WP monoshock with reworked main piston and settings for all models More comfort and increased bottoming control
The XC-W models are fitted with highly rigid, forged triple clamps with an offset of 22 mm, providing a solid grip on the forks for precise handling. They allow forwards and backwards adjustment of the handlebars in four different positions for optimum rider ergonomics.
WHEELS & BRAKES
The KTM wheels use lightweight, CNC machined hubs and high-end, black GIANT rims to combine maximum stability and ruggedness with minimum weight.
BREMBO brakes have been the standard equipment on KTM’s off-road range forever, and combined with the lightweight Wave discs with diameters of 260 mm front and 220 mm on the rear wheel, they remain the class-leading system when it comes to that crucial combination of stopping power and a transparent brake feel.
KTM’s proven cooling system routes the coolant from the cylinder head through the frame triangle directly to aluminum radiators made by WP Performance Systems. Due to flow calculated internal circulation and CFD optimized air ventilation, the system is superbly efficient. In addition, well thought-out radiator guards guarantee excellent protection against mud while at the same time serve as efficient crash protectors. All EXC-F’s are fitted with a radiator fan as a standard feature.
Noise limits have become challenging for every manufacturer to meet, prompting KTM to put a lot of effort into the development of their exhaust systems. All models are fitted with state-of-the-art exhaust systems which guarantee maximum performance, low weight and conformity with the mandated noise limits.
The tapered Neken handlebar is made of high-strength aluminum and can be is mounted in 4 different positions in order to suit different rider sizes. ODI lock-on grips make grip changes easy and do not require any wire or glue to be secured.
KTM’s advanced ´No Dirt´ foot pegs prevent clogging up the pegs, even when digging into the side walls of deep ruts.
Ergonomically perfect, the seat was shaped specifically for offroad requirements and features a new seat cover with foam padded stripes providing improved comfort and grip.
New seat cover improved comfort and grip
The lightweight, polyethylene tank on 2 strokes and polyamide tank on 4 strokes allows gauging the remaining fuel with just a quick glance, thanks to its see-through plastic. The filler cap features a ¼-turn bayonet mechanism with an orange quick-release button for extra fast refueling. All fuel-injected models are fitted with an integrated fuel pump system and an additional fuel level sensor, which indicates low fuel level via a warning light in the speedometer.
The air box design combines maximum protection of the air filter against soiling with maximum airflow and low intake noise. The large Twin Air filter is mounted in a stiff cage, which at the same time holds the system in place, allowing extremely quick filter changes in the field without tools while minimizing the risk of incorrect filter installation.
E-STARTER & BATTERY
All models are equipped with proven electric starter systems – a super beneficial feature once the going gets tough. A new and more capable, super lightweight 2 Ah Lithium-Ion starter battery provides even better starting of the engine especially at cold weather conditions and contributes to the low vehicle weight.
Stronger and super lightweight Lithium-Ion battery better starting
BODYWORK & ERGONOMICS
The bodywork design is a direct result of close co-operation between the KTM development department, Kiska Design and all KTM factory riders, achieving complete harmony between rider and bike. The results are well-balanced ergonomics and ideally shaped contact points, maximum freedom of movement for the rider, a low seat height and astonishing levels of comfort. Intelligent design is also manifest in details like the smart solution that guides the brake hose in the headlight mask, or the I-beam structures of the front and rear fenders, which help to ensure maximum stability, low weight and reduced dirt accumulation.
A brand new, tailor-made kit of graphics in conjunction with the Factory style orange frame lets the latest EXC-F and XC-W generation stand out, making the new bikes immediately recognizable at a single glance.
New graphics and orange frame high-end Ready to Race appearance
KTM 150 XC-W
150 XC-W is the ideal model for youngsters and everybody looking for the lightest offroad racing bikes on the market. ‘XC’ means cross-country. ‘W’ represents their wide-ratio transmission. ‘KTM’, as ever, stands for winning. While the KTM 150 XC-W may be the lightest racing Enduro’s money can buy, it remains a genuine KTM heavyweight in terms of performance and quality.
Within the heart of the 150 XC-W engine is a new cylinder that has a bore of 58mm. Compared to the predecessor model they feature a reworked exhaust port which is now CNC machined for more precise timing and improved interaction with the main power valve, which is made of a new raw part and CNC machined too. The result is improved power delivery and class-leading performance over the entire range.
Cylinder with machined exhaust port and new power valve high-end precision for improved power delivery and performance
The lightweight die-cast engine cases feature a high crankshaft position located close to the center of gravity, which results in optimum mass centralization for best ride ability. In addition, the engine body is extremely compact and this contributes massively to the low engine weight. For MY19 the seat of the kick start intermediate gear has been reinforced for better reliability. Thanks to a new clutch, the new clutch cover is narrower reducing the engine width by 10mm.
Optimized seat of kick start intermediate gear improved reliability
New clutch cover reduced engine width
The 6-speed transmission is now made by PANKL. All gears are totally reworked for optimum function and improved reliability. It has unchanged gear ratios fitting perfectly to the characteristics of the engine. An advanced “NO DIRT” gear lever design prevents dirt from blocking the joint of the lever guaranteeing safe activation of the transmission.
Reworked 6-speed transmission better function, improved reliability
A newly developed DS (diaphragm steel) clutch features a one-piece clutch basket combined with the primary gear made of high-strength billet steel. It guarantees unbeatable reliability and allows a reduction of the engine width by 10mm due to its compact rivet-less design. It is fitted with extremely heat-resistant steel carrier friction discs, which ensure a good disengagement of the clutch. These are pre-tensioned by means of a diaphragm spring, substantially reducing the operating force required to pull the clutch. The Brembo hydraulic system provides easy and precise operation.
Newly designed DS clutch very compact and reliable clutch system, reduced engine width by 10mm
The 38 mm Mikuni TMX flat slide carburetor provides smooth and controllable power all the way up to the rev limitation.
250/300 XC-W TPI
THE FUTURE OF 2-STROKE RACING
Combining top performance and outstanding ride ability, the KTM 250 and 300 EXC TPI are distinguished by the lowest weight in their class, intuitive handling and a unique style, along with the awesome READY TO RACE performance. TPI stands for „transfer port injection“, and the groundbreaking new 2-stroke technology represents another major step forward on a global scale, once again demonstrating KTM’s unrelenting and continuous commitment to 2-strokes as such. The benefits to owners are clear: besides huge improvements in fuel efficiency and clean exhaust emissions, the electronics do away with the need for re-jetting, no matter the elevation of the race venue, prevailing weather conditions and the like. Also, engine lubrication on the TPI models is automatic from a separate oil tank and electronically controlled oil pump, obviating the use of pre-mixed fuel-oil mixture.
A state-of-the-art 2-stroke engine featuring the revolutionary TPI fuel injection combined with a lightweight and agile chassis make the 250 EXC TPI the prime choice for extreme offroad use. No pre-mix thanks to an electronic oil pump, no jetting, but also low purchase and ownership costs make this bike the absolute top of its segment.
300 XC-W TPI
The 300 EXC TPI with its state-of-the-art TPI fuel injection and its super agile chassis sets a clear benchmark. Thanks to its unrivalled performance and ride ability it is the first choice when the going gets really difficult. There is no better power-to-weight ratio on the market in a standard bike.
The 250cc and 300cc 2-stroke generations have been known and respected for offering the most powerful 2-stroke performance in its segment. For MY2018 though, KTM underscored its continuous commitment to 2-stroke technology with its revolutionary TPI fuel injection. In combination with its state-of-the-art engine design these power plants are even more refined than ever. The compact 2-strokes are a great choice for advanced offroad rider’s conscious of their purchasing and maintenance budget.
The 250/300cc cylinders are fitted with the sophisticated TVC exhaust control and have a bore diameter of 66.4 and 72.0 mm. For the fuel injection, 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. The engine management system’s intake pressure sensor is connected via a small-diameter tube in the back of the cylinder.
The TPI engines are fitted with a 39 mm throttle body made by Dell’Orto. Power is controlled by a throttle valve while intake air data is provided to the engine management system by a throttle position sensor. An adjusting screw allows the idle speed to be set and a cold start device is provided, opening a bypass to supply extra air. Oil supplied by the automatic oil pump via an oil suction pipe is mixed with the incoming air to lubricate the moving engine parts.
An 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 moving engine parts. Using engine speed and throttle position sensor data, the engine management system’s precise electronic control of the oil pump ensures the perfect amount of oil for any given conditions, loads and engine speeds is added.
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 1:80. This means the oil capacity of about three quarters of a quart is sufficient for at least five tanks of fuel.
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 supporting the handling of the bike. 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 offroad events and rallies.
The KTM XC-W TPI 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.
ENGINE MANAGEMENT SYSTEM
The KTM 250 XC-W TPI and 300 XC-W TPI models feature the most modern engine management system (EMS) of any 2-stroke off-road motorcycle. The electronic control unit is located below the seat utilizing various sensor data such as intake and ambient air pressure, throttle valve position and water temperature, the control unit optimizes ignition timing and the amount of fuel to inject. Thanks to its automatic altitude and temperature compensation, there is no need for the rider or mechanic to set up the bike for the prevailing environmental conditions. An optional map select switch allows the rider to select an alternate map, providing a smoother power delivery. In addition for the 300 XC-W TPI the dealer can flash a RACE map to be activated as the alternative map.
In order to accommodate the power requirements of the upgraded engine management system, the TPI models are fitted with a powerful generator, rated at 196 W, just like on the EXC-F 4-stroke models, as well as the EXC-F voltage regulator.
The rugged 6-speed transmission features widely spaced gear ratios optimized for offroad duty. It provides precise and easy shifting. The KTM ‘No Dirt’ gear shift lever design prevents dirt from blocking the joint of the gear shift lever for safe and reliable shifting in any conditions.
KTM sets the benchmark in terms of 2-Stroke technology with its vast range of race winning motocross bikes. While many manufacturers may have turned their back on the development of the lighter weight range, KTM’s success in numerous off-road competitions with these motors, and especially for junior racing, is second to none. KTM provides a full-range of motorcycles with the intention of ensuring the junior can progress through the ranks with the same brand they are accustomed to from an early age. They are excellent alternatives for all those who search for an easy to ride motocross bike with an outstanding power-to-weight ratio and a less demanding technology compared to the 4-strokes. For MY 2019 all models feature all new chassis and lot of detail improvements making these bikes even faster than before.