2-stroke 125 exc 200 exc 250 exc 300 exc 4

2-stroke 125 exc 200 exc 250 exc 300 exc
4-stroke 250 exc-f 350 exc-F 450 exc 500 exc
six days 125 exc 250 exc 300 exc 250 exc-f 350 exc-f 450 exc 500 exc
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EXC MODEL LINE-UP 2012
revolution
goes on
After a very successful Motocross season last year with Tony Cairoli winning the MX1 World Championship
on the 350 SX-F factory machine in its first year of competition, KTM is now ready to make its mark on the
enduro segment with the same style and flair. The revolutionary new 350 EXC-F is the bike that is about to
turn the world of enduro upside down. This is a completely new EXC racing machine developed with the
support of David Knight and Johnny Aubert. It represents a new benchmark with its light-weight chromemoly chassis, the most modern bodywork and a new PDS rear suspension combined with the compact and
powerful new 350 EXC-F engine. The result is the ultimate enduro: playful handling, minimal weight and
perfect enduro engine characteristics - a package which delivers a so far unknown offroad riding pleasure.
Following a long enduro tradition, KTM offers a wide range of offroad models, which have all been reworked
for MY 2012, featuring new chassis and many new engine developments, just to name a few: The 250 EXC-F
engine has been further developed, the 350 EXC-F is a brand new category and the 450 and 500 EXC receive
completely new engines. From now on, all 4-stroke EXC engines are fitted with a state-of-the-art Keihin EFI
system. With its 2-stroke models, KTM has been playing in its own league for many years, updating its engines
year after year. Power valves, electric starters for 250/300 cc and 6-speed transmissions for all models are a
proven KTM standard. For MY 2012, improved engine performance and better handling make the lightweight
and inexpensive 2-stroke machines an even better choice when it comes to rough enduro riding.
CHASSISMODEL YEAR 2012
Frame Completely new
frames with a further developed PDS rear suspension system for all EXC
models. Following the proven KTM tradition, the frames are made of highquality, lightweight chrome-moly steel material in various profiles. Compared
to the previous EXC frames the MY 2012 frame design provides higher torsional
and reduced longitudinal stiffness providing better track stability in conjunction
with improved handling. In addition the chassis is specifically designed to absorb
energy created from the rear wheel impacts. To the aluminium frame trend of our
competitors, we have delivered a high-tech steel frame that weighs approx. 0.5 kg
less than the lightest competitor. In addition it is easier to maintain,
easier to work on and supplies more space for the tank and
other components.
PDS Rear Suspension
Why PDS for the
EXC line-up? More and more enduro
races are designed with hard-core, extreme rocky
sections, which can easily destroy any traditional
linkage system. Under those conditions the KTM
EXC models fitted with PDS rear suspension with
no suspension components below the swing arm
benefit massively from the high ground clearance.
In addition, PDS provides less maintenance, less
weight and easy access to remove the shock from
the bike within a few seconds.
The new EXC models are fitted with a completely
new, 7 mm longer PDS shock made by WP Suspension and a further developed geometry (the shock
is mounted flatter compared to PDS 2011) to offer
an improved rising rate character. It is fitted with
an improved piston and bushings that provide better
seal and friction properties to handle the higher
shaft velocities. A new spring retention and preload
system allow preload adjustment without the use of
hammer and punch. A wide range of adjustability
of rebound and high/low speed compression
damping are KTM standard features.
Swing Arm
All models are fitted with a new
cast aluminium swing arm. The single-component casting process allows unlimited geometry solutions
and eliminates any inconsistencies created by welding. Updated
mounting positions, slightly higher profiles and optimised flex are
supporting the frame and suspension characteristics.
Most importantly, it features a weight reduction of
300 grams for improved suspension action.
Front Suspension All EXC models are
feature the latest generation of 48 mm USD front forks
“made by WP in Austria”. Compared to MY 2011, the
forks are fitted with new seals and improved bushings
providing better sensitivity. New settings for each model
match the needs of the new chassis package perfectly.
CHASSISMODEL YEAR 2012
Airbox The new layout of the airbox was driven
by two main functions: optimised protection for
the air filter against dirt and maximum airflow for
increased performance. The engineers designed
different intake boots (between filter and throttle
body/carb.) for every displacement, which improve
the power significantly.
Bodywork The bodywork of the new EXC line-up
has already proven its qualities on the last year’s SX models. Super slim
ergonomics and excellent contact points between rider and machine were a
major target set by 10 times MX World Champion Stefan Everts. Stefan also
insisted on having a wider and 50 mm longer rear fender, which is fitted
with a new number plate support for Enduro. An extremely useful feature is
the incorporated lift handle in the outer rear fender,
which is well protected against dirt from the rear wheel.
The ability to change the large Twin-Air filter
quickly and without tools is the KTM standard.
Exhaust Silencer The 4-strokes have
new improved silencers that score points with a
modern and bigger profile, not only optically, but
also reducing the noise level to the FIM noise
emission regulations (112 dB(A)).
The 2-stroke silencers feature a modern
“two-component” technology. A strong plastic
holder is injection-moulded around the
aluminium housing to better attach the silencer
to the motorcycle.
Wheels The high-quality KTM
wheels with CNC machined hubs are KTM standard. New silver rims
do not only appear lighter, they also take the unavoidable damages
during tire changes much better than rims coated in any other
color. Spokes are now covered with noble zinc/nickel coating
which not only suits the silver rims optically, but also improves
corrosion resistance. With new nipples made of high-strength
aluminium the weight could be reduced by 200 grams per wheel,
which is an important feature supporting suspension action and
easy handling due to the reduced gyroscopic reactions.
CHASSISMODEL YEAR 2012
Cooling System The proven integrated
Tank The slim 9 litre tanks are made from
The 450 and 500 EXC are fitted with a radiator
fan in serial production.
The 4-strokes are fitted with the latest version
of fuel pump. In the PowerParts programme
there are available 13 litre tanks for all models
and for the 2-strokes also 10 litre tanks. The
well proven ¼-turn fuel cap allows easy and
quick refilling and features a push lock to
prevent against unwanted turning.
cooling system routes from the cylinder head
through the frame triangle directly to the radiators,
the removed tubing simplifies the radiator mounting and improves the air flow through the
radiators. A new T-connector with an optimised
fluid flow improves the heat dissipation.
lightweight translucent polyethylene.
Other equipment –
highest level The KTM EXC models in general
are known to be high-end and reliable products, which
everybody recognises at the first spot. The list of standard features include the comfortable hydraulic clutch,
tapered aluminium handlebars, Renthal grips and CNC
machined hubs. In addition there is the high-quality
robot welding of frames and a KTM tool kit, which allows
disassembling nearly the whole bike due to special
standardised screws.
Brakes
Brakes by Brembo are serial equipment of all
KTM offroad bikes and are combined with lightweight wave rotors which are the benchmark when
it comes to feel and brake performance.
250EXC-F
Cylinder
Head
Starter
The 250 EXC-F engine is
fitted in serial production
with electric and kick
starter. A new kickstarter
provides less weight and
better ergonomics. The
new electric starter system is similar to the one
of the 350 SX-F/EXC-F
and is now connected via
the alternator cover (for
MY11 it was embedded in
the left engine case).
Engine
Management
System (EMS)
The newly developed engine management
system by Keihin with electronic fuel injection
and 42 mm throttle body secures spontaneous and powerful response and maximum
performance. Automatic temperature and
altitude compensation are state of the art.
Time consuming re-jetting of carburettors or
engine stalls during fast throttle openings
are a thing of the past - an enormous advantage for the 250 EXC-F making it a lot more
user friendly. An optional map selector switch
gives the rider the ability to choose different
mappings which change the engine characteristic. In addition to this, the user setting tool
(PowerParts) allows the logging of data of the
bike with a laptop and to change the ignition
(± 2°) and the EFI mapping in just a few
mouse clicks.
The heart of the very compact
engine is the brilliant cylinder
head with two overhead camshafts
and DLC coated finger followers,
which activate the four titanium
valves (intake 30.9 mm, exhaust 26.6
mm). An optimised, fluidic developed
(flow calculation & simulation) intake
channel provides 10% more gas flow
and therefore significantly increases
the performance. The intake cam
shaft is carried over from MY 2011
while the exhaust cam shaft
features an optimised automatic
de-compressor profile.
Alternator The 250 EXC-F engine is fitted
with a new AC alternator with more capacity
(196 W instead of 130 W), which now runs in oil for
cooling. This new alternator secures enough energy
for the fuel injection system and lights etc. In order
to adapt the larger alternator to the engine and to
supply it with oil the engineers developed a new left
engine case and a larger ignition cover.
Exhaust
system
A new exhaust header combined
with the new rear silencer guarantee
the best performance and low noise
level, meeting the current rules for
enduro competitions.
ENGINE
The 250 EXC-F has always been known for its strong performance and it has
won several Enduro World Championships. The new generation presents itself
with a further developed, even stronger engine including fuel injection. This is
a major step forward to make this agile and lightweight enduro machine even
more competitive in the future.
350EXC-F
Cylinder &
Piston
A new piston has been
designed in order to provide
less compression. Compared
to the SX-F, a lower dome
on top of the piston and a
longer cylinder reduce the
compression ratio from
13.5 to 12.3 in order to
supply smoother engine
characteristics.
Engine
Management
System (EMS)
The newly developed engine management
system by Keihin with electronic fuel injection
and 42 mm throttle body secures spontaneous
and powerful response and maximum performance. Automatic temperature and altitude
compensation are state of the art. Time consuming
re-jetting of carburettors or engine stalls during
fast throttle openings are a thing of the past.
An optional map selector switch gives the option of
selecting 3 additional different mappings, changing
the engine characteristic. In addition to this, the
user setting tool (PowerParts) allows the logging of
the bike data with a laptop and to change the ignition (2° advance, 10° retard) and the EFI mapping
in just a few mouse clicks.
Train
Valve
&
Cylinder
Piston
The crankshaft turns an
intermediate gear, which
drives the cam chain and
at the same time acts as
balancer shaft and holds
the water pump. A hydraulic cam chain tensioner
secures a reliable tension
of the chain and therefore
precise cam timing.
Crank shaft
Compared to the SX-F model, the 350 EXC-F is fitted
with a new crank shaft with
heavier crank webs in order
to provide more inertia
for smoother power
delivery and
better traction.
Cylinder Head The DOHC cylinder head is
fitted with four ultra lightweight titanium valves
(intake 36.3 mm, exhaust 29.1 mm) in combination with
very small, just 8 grams light finger followers with DLC
(Diamond like Carbon) coating, which allow a high rpm
limit of 12,000 rpm. Compared to the SX-F engine new
cam shafts are developed for better, enduro specific
low-end performance. In addition the EXC cylinder head
is fitted with slightly softer valve springs, adapted spring
retainers and new spring seating washers.
ENGINE
When compared to the 350 SX-F, this is a new DOHC powerhouse that has been
especially developed for enduro. The 350 cc 4-stroke engine delivers a very broad
and tractable power band and a very dynamic, but energy-saving engine characteristic. With a peak performance of more than 45 hp the 350 EXC-F will be powerful enough to beat any 450 in the E2 class. Ultra-compact with 57.5 mm stroke
and 88 mm bore and fitted with a modern electronic fuel injection, the engine has a
very wide usable speed range and very efficient rideability – the most user-friendly
bike offering unparalleled riding fun. The dimensions of the 350 engine are close
to the 250 4-stroke motor at nearly the same weight (approx. 28.5 kg). The playful
handling is comparable to a 250 four-stroke and results mainly from reducing the
rotational masses to a minimum. Therefore the rider benefits more, the longer a race
goes on – no matter if professional or beginner.
350EXC-F
The new 350 EXC-F engine has two oil pumps
similar to the 250 cc engine. A pressure pump
supplies the crankshaft, piston, balancer shaft,
chain tensioner and valve train. Additionally it
supplies lubrication for the clutch and cools the
ignition. A suction pump evacuates the crank
housing and lubricates the gear box. It creates
a vacuum in the crank housing to increase the
engine performance.
Transmission
The newly developed 6-speed gearbox
was designed to suit the engine characteristics of the 350 EXC-F for any kind of
enduro riding, and it provides this with a
very precise shifting.
Lubrication
Alternator The 350 EXC-F engine is fitted
with a 196 W AC alternator with an integrated
one-way clutch for the starter. This new alternator
secures enough energy for the fuel injection system
and lights etc. Compared to the SX-F, the oil-cooled
rotor features a larger diameter, which provides
more inertia and requires a larger ignition cover.
A new one-piece clutch basket combined with the primary gear is made
of high-strength billet steel. It guarantees unbeatable reliability and
contributes to the narrow engine size due to its compact rivet-less
design. Additionally, it allows the use of thinner steel linings, which
makes the whole clutch package noticeably narrower. Compared
to the SX-F clutch, a newly developed diaphragm spring makes
it possible to implement an additional rubber damping system,
guaranteeing more reliability for the transmission and better
traction. The hydraulic clutch by Brembo in conjunction with
the diaphragm spring guarantees a very light operation and
good controllable modulation of the clutch.
Balancer
shaft
For balancing the oscillating masses, the
350 EXC-F engine has a balancer shaft
on the right side of the engine which also
acts as a water pump intermediate gear
and drive pinion gear for the camshaft.
This solution delivers a very compact
overall design of the engine. Due to the
reduced weight of the piston and the
lower rpm range the balancer weight of
the EXC-F engine does not require the
additional tungsten inserts
as fitted on the SX-F.
Clutch
Starter The 350 EXC-F engine features an
electric and kick starter in serial production. The
electric starter is located behind the cylinder and is
connected via the alternator cover to the flywheel,
which is fitted with a one-way starter clutch.
ENGINE
ENGINE
For years KTM has set the benchmark amongst the large capacity four-strokes,
but with the newly developed 450 and 500 EXC (449.3 / 510.4 cc) we have set
a new standard in their classes. The new SOHC engines feature an extremely
compact design, easier maintenance, improved durability and a massive weight
reduction of 2.5 kg to the predecessor. Together with the new EFI system on both
engines, the 450 and 500 provide unrivalled enduro specific performance and
rideability. And in combination with the all-new chassis, the package will be the
future for those who crave maximum 4-stroke performance combined with playful
handling in the E2 and E3 classes.
Packaging
Compared to the predecessor, the new engine generation
features a brand new engine design. Due to an improved
packaging, the dimension of the engine casing could be
reduced drastically – a major advantage is the higher ground
clearance, the frame tubes are higher due to the very compact
engine. One reason is the switch from a central balancer shaft
to a lateral balancer shaft with an integrated water pump. In
addition, the casing is now produced in die-cast instead of
sand-cast, so that the wall thickness could be reduced
for weight saving without reducing strength. A special
high-strength aluminium alloy guarantees high ductility for
maximum safety against damage. In order to make the engine
more user-friendly, the new generation features one common
oil circuit. This new package results in an amazing weight
reduction of 2.5 kg compared to the predecessor.
450EXC500EXC
Engine
Management
System (EMS)
Cylinder &
Piston
The cylinder has the same bore as MY2011 with
95mm, but is now fitted with a mechanical cam
chain tensioner (instead of hydraulic) and new chain
guides. New, lighter pistons for each model contribute
to the low vibration level. They are fitted with new
high-performance piston rings for reduced blow-by
and less oil consumption.
The newly developed engine
management system by Keihin
with electronic fuel injection and
42 mm throttle body secures
spon-taneous and powerful
response and maximum performance.
Automatic temperature and altitude compensation
are state of the art. A new 196 W AC oil-cooled
alternator secures enough energy for the fuel
injection system and lights etc. An optional
map select switch and the user setting tool
are available in the PowerParts programme.
Cylinder Head
The outer shape of the SOHC cylinder
head with titanium inlet and steel
exhaust valves is basically the same
as before, but the internal design
has been redesigned completely.
Flow-optimised inlet and exhaust
ports together with an improved
design of the combustion chamber
have been developed to best suit
the new EFI system for outstanding
power delivery and performance. The
cam shafts are carried over from the
predecessor, while a new design of
the water jacket in the cylinder head
provides a better heat transfer, which
is even safer with the standard
radiator fan.
The crankshafts with 63.4 mm
stroke for the 450 EXC and 72 mm
for the 500 EXC are equipped with
a new ultra-light connecting rod
produced from special high-grade
steel by Pankl. This guarantees
highest precision and reliability.
Crank
shaft
450EXC500EXC
Transmission
The 6-speed enduro gearbox
is well proven and was carried
over from MY 2011. It provides
easy and very precise shifting.
Balancer
shaft
Due to improved materials and the sophisticated
design, the KTM engineers managed to reduce
the oscillating masses in the engines drastically
(450: - 15%, 500: - 20%). Therefore it was
possible to mount a smaller, 0.5 kg lighter,
laterally located counter balancer instead of a
central one, which would need much more space.
It is also designed to hold the water pump wheel.
ENGINE
Starter
The 450/500 EXC are fitted with
electric and kick starter in serial
production. Basically the electric
starter system was carried over
from MY 2011 and is located
well protected behind the
cylinder. The new engine
features a smaller and
lighter starter motor
and a new kickstarter.
A new one-piece clutch basket combined with the
primary gear is made of high-strength billet steel.
It guarantees unbeatable reliability and contributes
to the narrow engine size due to its compact
rivet-less design. Additionally, it allows the use
of thinner steel linings, which makes the whole
clutch package noticeably lower (6.5 mm). A newly
developed diaphragm spring makes it possible to
implement an additional rubber damping system
guaranteeing better traction and more reliability for
the transmission. The hydraulic clutch by Brembo
in conjunction with the diaphragm spring guarantees a very light operation and good, controllable
modulation of the clutch.
Clutch
Lubrication The new engine family features
a newly designed oil circuit with two instead of
three oil pumps and only one common oil circuit.
The pressure pump lubricates the conrod bearing,
balancer shaft, valve train and supplies oil for
piston cooling. The suction pump evacuates the
crankcase from blow-by and oil. It lubricates the
clutch and the transmission.
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NEWS
»new frame (PDS)
» better handling
» new swing arm
» new PDS shock
» new wheels
» new bodywork
» new airbox
» air flow optimised intake boot (between
filter and carburettor) for better power
» new exhaust pipe for better power delivery
» optimized carb setting (needle position)
» new kickstarter (-80 g, better ergonomics)
125EXC
The 125 EXC is the ideal bike for youngsters in the E1 racing class and for those
who search for ultra light handling, minimum weight and reasonable cost to
purchase and maintain. The proven high engine performance, which sets the
benchmark in its class could again be increased for MY 2012 and will secure
the sympathies especially of young future champions.
200 EXC
The ideal combination of playful handling of a 125 and engine power close to a 250.
The 200 EXC is the perfect choice for everyone who is searching for the best handling and sufficient performance outside the standardised classes to have the most
fun in offroad riding at reasonable costs.
NEWS
»new frame (PDS)
»better handling
»new swing arm
»new PDS shock
»new wheels
»new bodywork
»new airbox
»new intake boot for better power
»new ignition curve for smoother ridability
»new kickstarter (-80 g, better ergonomics)
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250EXC
For years KTM has committed to the development of 2-stroke engines which are an
advantage against 4-strokes in many aspects. Unbeatable power-to-weight ratio,
low cost of purchase and maintenance, and a comprehensible technique which
allows a piston change without having studied machinery. The most modern engine
with electric starter and the enduro-specific 6-speed gear box in conjunction with
the new chassis make the new 250 EXC an unrivalled enduro machine for tough
enduro rides. Taddy Blazusiak already proved its qualities by winning the 2011
Indoor Extreme World Championship.
NEWS
» new frame (PDS)
» better handling
» new swing arm
» new PDS shock
» new wheels
» new bodywork
» new airbox
» new intake boot for better power
» new reed valve block for better
throttle response
300 EXC
The 300 EXC has proven its qualities in many offroad races over the past years. It
is known for its massive 2-stroke performance and torque. Equipped with a further
developed cylinder, the new engine with electric starter and 6-speed transmission
produces even more low-end power than before. With the new chassis providing
easier handling, the 300 EXC is the bike to choose when the going gets really tough.
NEWS
»new frame (PDS)
»better handling
»new swing arm
»new PDS shock
»new wheels
»new bodywork
»new airbox
»air flow optimised intake boot
»new reed valve block for
better throttle response
»new cylinder for increased low-end power
2 STROKE
six days 125 exc 250 exc 300 exc
SIXDAYS2012
»Frame coated in orange
»Machined triple clamps in orange
»Handle bar coated in orange
»Supersprox rear sprocket in steel/aluminium
»Rear brake disc protector (orange)
»Solid rear brake disc (no holes)
»“Camel” seat with special seat cover
»Engine protector for all models
»Cooling fan for all 4-stroke models
»Map select switch for 250/300 EXC
»Exhaust pipe protector carbon 2-stroke
»Silencers with special titanium Sixdays coating
»Wheels with black spokes and black GIANT rims
»Front axle puller
»Quick-change bolt for rear brake pads
»Exclusive Six Days graphics (Finland)
4 STROKE
six days 250 exc-f 350 exc-f 450 exc 500 exc
x-seat
Not just motorcycles – but a complete range of KTM designed casual and functional PowerWear expects
the potential enduro rider at any KTM dealership. Useful accessories that make any ride the perfect
one, fashionable items to show orange affection at after ride gatherings or KTM gift articles for the real
offroad fans! All KTM PowerWear items have been tested and developed together with our Enduro World
& National Champions.
body armour
user
setting tool
baja
hydration
pack 1650
team tee
ktm neck
brace adv II
slipon factory
silencer
Pimp your bike – choosing from the vast original KTM PowerPart product range!
Be it visual or acoustic, there´s many ways to stand out from the crowd and
make “Ready to Race” motorcycles look and sound even cooler. Original KTM
PowerParts help riders to finetune their KTM to their personal riding style,
without worrying about warranty or functionality – for example with the
“User setting tool” (do-it-yourself tuning on the laptop in all rev ranges).
All KTM PowerParts items have been tested and developed from KTM´s official
R&D department together with our Enduro World & National Champions.
2-stroke 125 exc 200 exc 250 exc 300 exc
4-stroke 250 exc-f 350 exc-F 450 exc 500 exc
six days 125 exc 250 exc 300 exc 250 exc-f 350 exc-f 450 exc 500 exc
Photos: A. Barbanti, H. Mitterbauer, P. Friedl
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