R&D SECRETS OF THE ALL-NEW KTM FACTORY EDITIONS

On Jan 10, 2015 Last updated Jan 10, 2015

Ryan Dungey and his new “Ryan Dungey Replica.”

Ryan Dungey was the original impetus for the 2012 KTM 450SXF-FE Factory Edition. The first model, four years ago, was a giant step forward for KTM, but the latest model, the Factory Edition IV, is a game changer. It weighs 226.2 pounds, which makes it the lightest 450cc production motocross bike on the showroom floor. Ryan and teammate Dean Wilson will not only get the lightest bike, but it has a completely new engine, frame, shock linkage, swingarm, shock, footpegs and only a small handful of parts aren’t changed from the current model. The 250SXF shares the same revolutionary design changes as the 450SXF. The 2016 350SXF will get all the frame, chassis and setup improvements, but will use the same engine as last year. The KTM two-strokes will also get the chassis updates, but there are some more two-stroke surprises in store.

MXA wants to show you some of the R&D behind the development of the 2015-1/2 Factory Edition IV — because this technology will be on the 2016 KTMs when they hit the showrooms this summer.

2015-1/2 KTM 450SXF Factory Edition IV.

Not only will the 450SXF have an new engine and chassis, but it also gets a handlebar-mounted map switch. Three maps are available (stock, mellow and aggressive). Helping the maps is a gear position sensor that tells the black box what gear the bike is in so it can generate a fuel and ignition map perfect for that gear. A launch control system has also been added to help the engine hook up off the line. Good news for short riders, the seat is 20mm lower at the rear fender and 10mm lower in the center. The handlebars are 10mm lower to maintain last year’s bar/seat relationship.

2015-1/2 KTM 250SXF Factory Edition I.

The 2015-1/2 KTM 250SXF Factory Edition is new this year. There has never been a 250 FE before. It gets a totally new engine, chassis and design. Just like the 450, the 250SXF-FE gets three maps, launch control and a gear selector sensor. The rev limiter is set at 14,000 rpm. The clutch features a steel one-piece basket that is lighter than last year. The number of plates has been reduced from 8 to 7 and the master cylinder has been reworked for a lighter pull.

This overlay shows the how much smaller the new 250SXF engine is than last year’s engine. The new engine is 2.4 pounds lighter than the old engine. The new, lighter, five-speed transmission is 8mm narrower and features a new surface treatment on 1st and 5th gears along with a special low-friction coating on the shift forks to provide precise and easy shifting.

Just for comparison, this is the current KTM 250SXF engine as used for the last few model years. The all-new 2015-1/2 engine, which will be the 2016 250SXF engine, is shown below.

The new 250SXF engine has been completely redesigned: (1) The crankshaft has been moved up 6mm. (2) The connecting rod is 6mm shorter. (3) The clutch is moved 11.1mm rearward and 26.9mm up. The overall engine is 20mm shorter than last year. (4) The camshafts are 150 grams lighter. (5) The finger followers have a 30 percent harder DLC coating. (6) The cylinder is 130 grams lighter. (7) The big end bearings don’t use balls, but are force-fit bearing shells that run directly on the crank pin and can withstand the 250SXF’s high rpm.

The new frame (right) is almost one pound lighter (13.4 ounces) than the old frame (left). Additionally the new frame is 20 percent stiffer in torsion and 30 percent more resilient longitudinally.

The grey frame is the new one (overlaid on the old frame). The new chassis utilizes symmetrical tubes on both the left and right side to control flex and feel. The head stays are attached to the head from the rear to reduced vibration. The triangle’s tubes are 6mm wider and 2mm narrower in profile.

The new subframe (dark color) is much smaller than the old subframe. It is also close to 9 ounces lighter than its predecessor.

KTM designed a completely new swingarm that features not only a new outer shape, but its inner walls have thick and thin wall diameters to create flex characteristics that match the frame’s more resilient feel. The new swingarm is a half-pound lighter than the previous swingarm.

The footpegs are larger and feature an open draft design to help them shed mud quicker. Of course, they are lighter than last year’s pegs.

This diagram show what the new footpegs look like from underneath (the front is to the right). By extending the footpeg pivot area, KTM created a scraper that cleans mud out of the pivot every time it moves up or down.

The upper triple clamp now comes with rubber-damped handlebar mounts to reduce vibration. The bar mounts are reversible for optional mounting positions and the lower bar mount is now one piece.

KTM owners will never struggle to get their air filter properly aligned in the future. The new air filter cage has two pins that align into plugs so that you can install the filter in seconds. Additionally, the airbox volume extends rearward to the inside of the left number plate (and for next year the side plates are removable — because they are no longer a one-piece design with the rear of the airbox). The airboot, between the filter and throttle body, is made of a space-age material that is structurally stiffer than KTM’s previous rubber boot (so that it won’t deform under air pressure surges) and is 10 ounces lighter than the old boot.

KTM’s engineers put lots of thought into their radiator design. Rather than just put old-school plastic guards on the front of their radiators, KTM used wind tunnels to design a new radiator guard shape that flows more air (and is made from a stiffer plastic to help the flow and act as a radiator brace). The radiator shrouds also seal against the outer edge of the radiators to direct airflow into the radiator’s cores. There is a new filler cap and filler neck that seals better than last year’s design. The end result of all of this work is that the exact same capacity and surface area produces 10 percent better cooling efficiency

The old 44mm throttle body (left) attaches the throttle cables to a cam that is connected to the throttle body’s butterfly valve by a linkage arm. KTM’s new Direct-Connect throttle body doesn’t use any linkage. The throttle cables attach directly to the butterfly valve. The end result is more accurate throttle modulation and a 100 gram weight savings.

Click here to subscribe to MXA: https://hi-torque.com/motocrossaction

TECH SPECS ON THE 2015-1/2 KTM 450SXF FACTORY EDITION IV

450SXF FACTORY EDITION ENGINE

The Factory Edition engine is 4 pounds lighter than the current 450SXF engine.

• The new 450 SX-F engine design is more compact, lighter and provides higher performance throughout the entire range of power.
• New electronic Launch Control for efficient starts and multiple engine maps to control the overall power delivery.

The Factory Edition 450 cases are laid on top of the current engine cases to show that they are almost one inch shorter. They are also almost one inch narrower.

• New engine cases redesigned to centralize the rotating mass of the crankshaft and clutch and reduce overall length by 23mm and width by 23mm.
• New cylinder head combustion chamber geometry, optimized ports, shorter timing chain and friction reduced chain guides for improved power and reduced weight.

The 450SXF factory Edition IV engine uses 6.4mm shorter connecting rod, but the same bore and stroke.

• New 6mm shorter cylinder, lightweight piston connected to a shorter con-rod and a crankshaft with 10% more inertia contribute to the compact design, light engine feel and massive power
• New lighter 5-Speed transmission that is 8mm narrower and features a new surface treatment on 1st and 5th gears along with a special low- friction coating on the shift forks to provide precise and easy shifting.
• DDS (Damped Diaphragm Steel) clutch has a new lighter basket along with a reworked inner hub and pressure plate providing better oil supply and improved cooling of the clutch.

KTM eliminated the throttle body’s linkage pulley system and connected the throttle cables directly to the butterfly pulley. It is 100 grams (approximately 3.3 ounces) lighter.

• Completely reworked Keihin Engine Management System with new 44mm throttle body featuring a lightweight direct-connect design
• New super compact and lightweight 1.1lb Lithium-Ion starter battery.

Between the new battery and smaller starter motor the starting system is over two pounds lighter.

• New WP flow optimized radiator design features a substantial improvement in engine cooling.

It may look like a two-stroke expansion chamber, but it actually a stylized resonance chamber that fits over the existing head pipe. KTM calls it FDH which sounds like a florist shop. The 250SXF Factory Edition has the old school tube-style resonance chamber.

• New Flow Design Header (FDH) with an integrated sound resonator that is also designed to increase power along with a new lightweight silencer that is 40mm shorter than the previous design for quick throttle response.

450 SXF FACTORY EDITION CHASSIS

The shock linkage is 3.2mm longer than the previous link. It works in conjunction with a new bell crank and shorter shock. The swingarm is 250 grams lighter. If that doesn’t sound like much, think again. 250 grams is one-half pound (all of it unsprung weight).

• New chromoly steel frame provides 20% more torsional rigidity with 30% less longitudinal stiffness resulting in improved handling and energy absorption.
• New smaller, lighter subframe design made with new aluminum profiles.
• New lighter swingarm features a revised internal structure to match the new frame characteristics.
• New lighter footpeg design that provides a larger surface area and features a “scraper” to reduce dirt build-up in the hinge.

The 22mm offset triple clamps feature rubber-mounted handlebars, Neken handlebars (Neken private labels bars for a very famous handlebar brand), a one piece bar clamp (under the bars) and fore and after bar mount adjustment.

• New CNC machined upper triple clamp features a rubber damping system for the new Neken handlebar and ODI lock-on grips.
• The advanced WP 4CS (Four Chamber System) fork features revised damping settings optimized for the new chassis.
• New generation WP shock has been developed in conjunction with the new frame and swingarm architecture including a new linkage/pullrod system.

There is a new throttle assembly that incorporates the cable adjusters into it. Additionally, KTM has removed the heavy rubber housings from the throttle cables for snappier response.

• Both the 250 and 450 Factory Editions use super lightweight Galfer Wave rotors, CNC machined hubs, high-end Excel rims and Dunlop Geomax MX32 tires.
• New airbox and air filter design offers maximum protection for the engine while ensuring maximum airflow and providing quick “no tools” air filter changes.

The number plates can now be removed separately (they have been part of a one-piece unit — combined with the back of the airbox). The muffler is 40mm shorter and moved forward 60mm.

• New ergonomics and bodywork centralize mass.
• The new 2015 450 SX-F Factory Edition weighs only 226.2 pounds.

The Factory Edition IV is the first production bike to come spec’ed with Dunlop MX32 tires.

Click here to subscribe to MXA: https://hi-torque.com/motocrossaction

TECH SPECS ON THE 2015-1/2 KTM 250SXF FACTORY EDITION I

250SXF FACTORY EDITION ENGINE

The 250SXF Factory Edition engine has its crankshaft moved up 6mm, the clutch shaft moved back 11.1mm (and 26.9mm up) and the engine itself is 20mm shorter than the current 250SXF engine.

• The new 250 SX-F engine design is more compact, lighter and provides higher performance throughout the entire range of power.
• New electronic Launch Control for efficient starts and multiple engine maps to control the overall power delivery.
• New cylinder head combustion chamber geometry, optimized ports, camshafts, timing, finger followers and valve springs for improved power and reduced weight.

The new cases (on top) are much smaller than the current 250SXF engine cases (on bottom). The smaller engine weighs 2.4 pounds less than the old engine.

• New engine cases redesigned to centralize the rotating mass of the crankshaft and clutch and reduce overall engine length by 20mm.
• Completely reworked Keihin Engine Management System (EMS) with new 44mm throttle body featuring a lightweight direct-connect design.

The new shift tip is design to avoid mud clogging. There is a scraper on the backide of the tip that self cleans the spring-loaded portion. To resolve the issue of the current shift lever being too low, KTM lowered the footpegs 4mm on the frame and moved them back 5mm.

• New 5-speed transmission features wider gears with a new surface treatment on the 2nd, 3rd and 4th gears along with a special low-friction coating on the shift forks to provide precise and easy shifting.
• New lightweight forged bridged box-type CP piston, shorter connecting rod mated to a new stiffer crankshaft contribute to a light engine feel and strong power delivery.

The new lithium iron phosphate LiFeP04 battery is 2.2 pounds lighter than the current Yuasa lead acid battery.

• New CSS (Coil Spring Steel) one-piece clutch that has been completely redesigned for improved oil supply for better cooling, durability and lighter weight.
• New super compact and lightweight 1.1lb Lithium-Ion starter battery.
• New WP flow optimized radiator design features a substantial improvement in engine cooling.
• New exhaust header and new lightweight 40mm shorter silencer are both designed to increase power and contribute to mass centralization.

250 SXF FACTORY EDITION CHASSIS

• New chromoly steel frame provides 20% more torsional rigidity with 30% less longitudinal stiffness resulting in improved handling and energy absorption.

The Factory Edition subframe (grey) is 250 grams lighter than the previous, and larger, subframe.

• New smaller, lighter subframe design made with new aluminum profiles.
• New lighter swingarm features a revised internal structure to match the new frame characteristics.
• New lighter footpeg design that provides a larger surface area and features a “scraper” to reduce dirt build-up in the hinge.

KTM routed the front brake hose behind the front number plate, eliminating the need for a cable guide. The front fender has been redesigned with a lower i-beam section of improve air flow to the radiators.

• New CNC machined upper triple clamp features a rubber damping system for the new Neken handlebar and ODI lock-on grips.
• The advanced WP 4CS (Four Chamber System) fork features revised damping settings optimized for the new chassis.

The new WP shock has a larger gas reservoir, smaller inner shaft and shim, plus a 12mm shorter overall length. It is attached to a new linkage that provides 10mm more travel, even though the shock is 12mm shorter. The pull rods are now 148.2mm long (they were 145mm).

• New generation WP shock has been developed in conjunction with the new frame and swingarm architecture including a new linkage/pullrod system.
• Both the 250 and 450 Factory Editions use super lightweight Galfer Wave rotors, CNC machined hubs, high-end Excel rims and Dunlop Geomax MX32 tires.

KTM’s new airbox design is very clean and simple. The air filter cage plugs into the hole on the white portion at the back of the airbox. Then, the front of the cage is held by the clip in the lower part of the front of the airbox. It means that the air filter can never be misaligned.

With the air filter in place you can see how it works. There are no tools needed to get into the airbox and no wing nuts used to hold the air filter.

• New airbox and air filter design offers maximum protection for the engine while ensuring maximum airflow and providing quick “no tools” air filter changes.
• New ergonomics and bodywork centralize mass, improve handling and rider comfort.
• The new 2015 250 SX-F Factory Edition weighs only 221.6 pounds.

With a 221.6 pound weight, the 2015-1/2 KTM 250SXF Factory Edition is the lightest 250 four-stroke sold. And, it is achieved this weight with an electric starter and battery.

R&D SECRETS OF NEXT YEAR’S KTM AND THIS YEAR’S FACTORY EDITIONS

Ryan Dungey and his new “Ryan Dungey Replica.” The retail price of the 250SXF Factory Edition will be $9299, while the 450SXF Factory Edition IV will retail for $10,199.

MXA wants to show you some of the R&D behind the development of the 2015-1/2 Factory Edition IV — because this technology will be on the 2016 KTMs when they hit the showrooms this summer.

2015-1/2 KTM 450SXF Factory Edition IV.

2015-1/2 KTM 250SXF Factory Edition I.

Just for comparison, this is the current KTM 250SXF engine as used for the last few model years. The all-new 2015-1/2 engine, which will be the 2016 250SXF engine, is shown below.

The new frame (right) is almost one pound lighter (13.4 ounces) than the old frame (left). Additionally the new frame is 20 percent stiffer in torsion and 30 percent more resilient longitudinally.

The footpegs are larger and feature an open draft design to help them shed mud quicker. Of course, they are lighter than last year’s pegs.

The upper triple clamp now comes with rubber-damped handlebar mounts to reduce vibration. The bar mounts are reversible for optional mounting positions and the lower bar mount is now one piece.

Click here to subscribe to MXA: https://hi-torque.com/motocrossaction