The 2016 KTM Model Range has been launched in Italy overnight with a host of changes made to the full range of KTM SX Machinery.
At this point in time there looks as though there will be some key differences between the European spec bikes and the American spec bikes, with the Australian market set to receive the American spec bikes that we have now confirmed with through KTM Australia.
The big difference between the two Euro and U.S.A spec bikes is the forks with the European models set to receive an all new WP 48mm USD air-sprung fork developed by WP Suspension in close collaboration with KTM.
The other main point of difference will be a four speed gear box for the Euro models while the Australian and American version will retain a five speed gear box.
“We will get the US spec versions here in Australia.” KTM Australia Marketing & Communications Manager Greg Chambers confirmed to fullnoise.com.au “The main difference being that the US spec has the developed 4CS fork fitted whereas the European spec has the new air fork fitted. The 450 SX-F also has a 5-speed box rather than the 4-speed in Europe.”
“We chose the US spec as our SX models are used across varied disciplines here in Australia from motocross to desert and believe the 4CS has proven itself across these terrains. Plus we’ll get the advantage of a further 12-months development on the air fork before making a decision on the spec of our 2017 models.
“We’ll get certain models as early as August with the full range on dealer floors in September.”
It is a split fork with separate functions for each fork leg. The damping functions are on the right side, whereas the air spring is in the left. The left leg features a capsuled air cartridge.
Another noticeable change for 2016 for the model range is the frame changing back from the popular orange in 2015 to a black steel frame for 2016.
Below are the official changes to the 2016 450SX and 250SX that are available on the KTM international web site.
Check out gallery of KTM’s full 2016 Motocross lineup below>>
General Changes Across the Four Stroke SX-F Range:
Airbox – The new airbox design offers maximum protection of the air filter against soiling, while ensuring maximum airflow in conjunction with new and 300 g lighter intake snorkels that are made of a new material (reducing the deformation due to air intake pulses) for improved performance. As found on previous models, the new Twin Air filter is easier and safer to mount and can be changed without tools in seconds, a standard, original feature by KTM. Battery and wiring harness
As in the past, all new SX-F engines are fitted with the proven electric starter – a unique KTM feature and a major benefit at all levels of motocross racing. For MY 2016 the SX-F range fits a super compact and lightweight 495 g lithium-ion starter battery into a standard motocross bike, providing safe starting of the engine and reducing the weight by 1 kg over MY 2015!
Seat – Ergonomically perfect, the new seat has a higher foam volume, which offers great comfort and durability at the same time, while weighing the same as the previous model.
Frame – The new frame design provides approximately 20 % higher torsional rigidity and 30 % less longitudinal stiffness, with newly designed engine stays for less vibration. This increased flexibility results in better absorption of the energy created from the front and rear wheel loads supporting the suspension for more comfort and less rider fatigue. A 0.4° steeper steering angle and a 10 mm shorter wheel base contribute to better handling and last but not least it´s around 380 g lighter than the previous model.
Footpeg – A new sophisticated “No-Dirt” footpeg solution prevents dirt from blocking the pegs in order to bring them back into position, even when digging in deep ruts. In addition the new footpegs are larger and more stable, provide better grip and they are also lighter than on previous models.
EURO Spec Forks – The KTM SX models are fitted with a revolutionary new and super-lightweight WP fork, a 48 mm USD air-sprung fork developed by WP Suspension in close collaboration with KTM. It is a split fork with separate functions for each fork leg. The damping functions are on the right side, whereas the air spring is in the left. The left leg features a capsuled air cartridge.
This air spring is easy to adjust to any rider weight via a single air valve and a standard fork air pump. The right fork leg integrates a completely new damping cartridge to fit single damping leg requirements, and the damping can be adjusted to the track conditions or the rider’s preferences with a twist of a dial. The new fork with approximately 300 mm travel has outstanding response and excellent, very consistent damping characteristics, while also with a reduced weight of 1.4 kg compared to its predecessor. Triple clamp
Monoshock – The new generation of monoshock made by WP Suspension has been developed for the new SX models in conjunction with the new frame and swingarm architecture, including the reworked linkage system and the new WP forks. The linkage system has also been reworked with a revised geometry and longer pull rods, which was tested last season in most of the KTM factory bikes.
Triple Clamps – Top quality, CNC-machined triple clamps have been something of a KTM trademark for years. Ensuring a precise handling, they perceptibly support the flex characteristics, and with it, the action of the forks. For MY 16 the upper triple clamp features a newly developed rubber damping system for the handlebar clamp in order to reduce the vibration level of the handlebar. The clamps retain their forward and back adjustability for any rider preference.
Weight reduction – The main target for the KTM engineers when developing the new SX generation was a massive weight reduction in conjunction with an improved handling. The result of between 4 and 5 kg is outstanding making the new KTM models the lightest bikes in the competition, even though the 4-strokes are equipped with a super-beneficial electric starter as a standard feature, while the competitor models need to be kickstarted.
Wheels – The 450 SX-F is fitted with lightweight, CNC-machined hubs, high-end Excel rims and new, weight reduced spokes with lightweight aluminium nipples providing maximum stability at minimum weight. The latest MX tires from Dunlop (Geomax MX 32) have been developed from KTM factory racing in the USA, factory testing and expert rider feedback in racing. They guarantee perfect traction and outstanding performance.
Brakes – High-tech Brembo brakes have always been standard equipment on KTM offroad bikes, and are combined with newly designed and weight-reduced Wave discs made by GALFER featuring also an improved heat resistance. The ultimate solution in braking technology. Weight reduction front 63 g, rear 32 g.
Swingarm – As on the predecessor models, the new SX generation features a reworked cast aluminium swingarm. The updated design offers reduced weight and an optimized flex behavior supporting the frame and suspension created with a single-component casting process. The weight reduction is 250 grams.
Bodywork – For the new generation of SX models the KTM factory riders were involved in shaping the bodywork together with the specialists from KTM R&D and Kiska Design. The goal was to achieve complete harmony between rider and bike down to the finest details. The results are all-new plastics that provide perfect ergonomics and contact points for the rider, maximum freedom of movement, a lower seat height of between 10 to 20 mm (rear end) and better comfort, especially in the rear part of the seat.
Fuel tank – All models of the SX range have new lightweight polythene tanks with a capacity of 7.0 liters of petrol. The filler cap with an inside thread makes for an easy and reliable closure. The 4-stroke models are fitted with an integrated fuel pump system.
Graphics – New modern in-mold graphics highlight the sporty character of the MY 2016 SX range of cutting-edge Motocross bikes.
Cooling system – The proven integrated KTM cooling system routes the coolant from the cylinder head through the frame triangle, directly to newly developed aluminium radiators made by WP, which have a new filler cap system and are made of a stiffer alloy. Due to flow optimized internal circulation and CFD-calculated air ventilation, the cooling efficiency has been improved by approximately 10 % and the sophisticated radiator guards provide efficient protection in case of crashes.
450 Engine – With new features such as its much more compact dimensions, stronger performance throughout the rev range and a weight reduction of 1.8 kg, this newly developed powerplant is the lightest 450 engine on the MX market. With a reworked single overhead camshaft cylinder head and the latest electronic fuel injection, it is distinguished by unrivalled power of more than 62 hp and a highly efficient power delivery.
Cylinder head – Inside the newly designed cylinder head with its reworked water jacket and combustion chamber, the gas flow through the optimized ports is controlled by an all-new overhead camshaft. This activates four ultra-lightweight titanium valves via extremely rigid rocker arms, which are DLC coated on the intake side. This configuration allows engine speeds of up to 11,500 rpm. In addition, the head is 350 g lighter than the previous model due to the compact design. Cylinder head and piston
In the reworked and 6 mm shorter cylinder, featuring an optimized water jacket and a bore of 95 mm, is an extremely lightweight box-in-box type piston together with a weight optimized piston pin that delivers a major contribution to the engine’s low vibrations and engine-speed strength. The compression ratio is 12.6:1.
Crankshaft – The 450 SX-F’s crankshaft features 10 % more inertia (without increasing weight) and utilizes a shorter connecting rod over the previous model, which contributes to an overall compact and light engine with a snappy power delivery. A higher balancing factor reduces the vibration level. A plain big end bearing with two force-fitted bearing shells runs directly on the crank pin, and the oil feed for this is ensured by the engine’s pressure lubrication. An overall design that offers the customer lengthened service intervals.
Counter balance shaft – The weight optimized, side-mounted counter balance shaft at the same time drives the water pump. Thanks to the perfect mass balancing and this powerhouse’s low total oscillating masses, engine vibrations can be kept to a minimum even at the highest engine speeds.
Engine cases and covers – The completely new design of the die-cast engine cases allows for a much more centralized shaft configuration, raising the crankshaft by 7 mm and 9 mm backwards closer to the bikes center of gravity – a weight saving of 550 g and a weight reduction to 27.3 kg (EU), 27.8 kg (USA). Newly designed engine covers made of magnesium feature an advanced surface structure in order to reduce the wear caused by the rider’s boots.
Clutch – The 450 SX-F employs the KTM-developed DDS clutch (Damped Diaphragm Steel) with 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 sufficient space for a damping system integrated into the clutch hub, which benefits for both traction and durability.
Transmission – The new engine of the 450 SX-F uses a lightweight 4-speed gearbox with unchanged gear ratios that are perfectly matched to the power delivery of the large displacement engine. In addition the 1st and 3rd gears are now treated with a special surface treatment for better reliability. On the US market, the 450 SX-F is delivered with a 5-speed gearbox in order to meet the demands of the American customers using the bikes on faster tracks and for desert rides.
350 SX-F Engine – The new DOHC (Double Overhead Camshaft) engine of the 350 SX-F features a completely new construction in order to make it even more compact and powerful than before. Fitted with the latest electronic fuel injection system and electric starter, it has a very wide usable speed range, high performance and incredibly efficient rideability. The new design made the engine 20 mm shorter than previously, while reducing the weight by 1 kg to only 27.2 kg.
Cylinder head – The new cylinder head features an improved combustion chamber geometry, two overhead camshafts with a friction-optimized super-fine surface, new finger followers with a 30 % harder DLC coating and high-flow ports. In conjunction with new valve springs and retainers for the four lightweight titanium valves (intake 36.3 mm, exhaust 29.1 mm) the flow rate has been maximized for an optimal power band, with more performance across the entire range, which ends at an engine speed of 13,400 rpm. The peak performance now is at 58 hp.
Cylinder and piston – In the redesigned and shorter cylinder, with a bore of 88 mm, works a weight reduced forged bridged box-type piston made by CP. Its new piston crown geometry is adapted to the new high-compression combustion chamber and stands out with its extra rigid structure, combined with a low weight. The compression ratio is at 14:1. Thanks to the low oscillating masses, the engine offers extremely lively characteristics.
Crankshaft – The new 350 SX-F’s crankshaft is lighter and features a stiffer design than previously. It utilizes a shorter connecting rod, contributing to the compact and light engine with a typically snappy power delivery. This design is a major prerequisite for the extremely high engine speed levels and the unrivalled maximum power of the 350 cm³ engine. Not only that, it enhances the engine’s durability, allowing long crankshaft service intervals.
Clutch – The highly compact CSS clutch (Coil Spring Steel) features a weight reduced, wear-free steel basket, and now seven instead of eight clutch plates, which are extremely heat resistant due to their steel carrier discs. In addition, a reworked inner hub and a pressure plate guarantees a better oil supply along with even better cooling of the clutch. A smaller master cylinder diameter of the Brembo hydraulic clutch system provides easier and precise modulation.
Transmission – The new engine is fitted with an all-new and weight reduced, five-speed gearbox. It features the same gear ratio as the previous model, but has wider gear sprockets, featuring a special surface treatment on the 2nd, 3rd and 4th gears for improved reliability. One of the new and special features on the bike is an advanced “NO-DIRT” gear lever design, which prevents dirt from blocking the joint of the lever and guarantees a safe activation of the transmission.
350 SX-F engine cases and covers – The completely new design of the die-cast engine cases allowed for a much more centralized shaft configuration, raising the crankshaft by 6 mm closer to the bike’s center of gravity. Newly designed engine covers made of magnesium feature an advanced surface structure, which reduce the wear caused by the rider’s boots.
Engine management system – The completely reworked Keihin Engine Management System, with electronic fuel injection, features an all-new 44 mm throttle body, which provides a spontaneous response and maximum performance thanks to a revolutionary injector position. The new ECU (Engine Control Unit) includes a launch control for more efficient starts with the provision of different maps according to the gear sensor selection. In addition, the rider can activate an optional map for a different power delivery via the map select switch on the handlebar.
Counter balance shaft – In order to balance the mass-forces, the new 350 SX-F engine also uses a multifunctional counter balance shaft, which at the same time drives the water pump and timing chain. It features newly designed sprockets fitted to the new timing chain. Massive weight reduction
250 SX-F Engine – The new 250 SX-F engine is based on the similar overall design of its predecessor, with some major refinements to make this MX2 power plant more compact and lighter, with the production of improved torque and power across the entire rpm range. Perhaps one of the most impressive benefits of the new design is a weight reduction of 1.1 kg to a total of 26.1 kg, including the incredibly beneficial electric starter.
The reworked power unit guarantees an improved power curve over the entire rev range up to 14,000 rpm, which makes the new 250 SX-F much easier to ride for both amateur and professional riders.
Cylinder head – The centerpiece of the compact DOHC (Double Overhead Camshaft) engine is the new cutting-edge cylinder head. It features improved combustion chamber geometry, two 150 g lighter overhead camshafts with new timings, plus a friction-optimized super-fine surface, new finger followers with a 30 % harder DLC coating and a reworked timing drive (friction reduced and shorter DID timing chain, new sprockets and chain guides). New valve springs and retainers for the four lightweight titanium valves (intake 32.5 mm, exhaust 26.5 mm) and high-flow ports create a maximized flow rate for an optimal power band and maximum performance, which concludes at an engine speed “sound barrier” of 14,000 rpm.
Cylinder & piston – In the reworked and shorter cylinder that has a bore of 78 mm, is a weight-reduced, forged bridged box-type piston made by CP. It features a unique piston ground shape adapted to the new combustion chamber and stands out with its extra rigid structure, combined with a low weight. The compression ratio is at 14.4:1. Thanks to the low oscillating masses, the engine offers extremely lively characteristics.
Crankshaft – The new 250 SX-F’s crankshaft features a stiffer design and employs a 6 mm shorter connecting rod, contributing to the compact and light engine with a snappy power delivery. A plain big end bearing features two force-fitted bearing shells run directly on the crank pin. This design is a major prerequisite for the extremely high engine speed levels and the unrivalled maximum power of the 250 cm³ engine. Not only that, it enhances the engine’s durability, allowing long crankshaft service intervals.
Counter balancer shaft – In order to balance the mass-forces, the new 250 SX-F engine uses a multifunctional counter balance shaft, which at the same time drives the water pump and timing chain. It features new sprockets fitted to the new timing chain.
Electric starter – The new 250 SX-F is again fitted with an electric starter as standard, which is well known as a clear advantage when it comes to crunch time in the heat of battle. A new starter motor made by Mitsuba (modified for easy disassembly) and a weight reduced starter drive guarantees more efficient and reliable starting.
Engine cases and cover – The completely new design of the die-cast engine cases allowed for a much more centralized shaft configuration. This and further developments make the engine shorter by 20 mm, while contributing to a much more centralized mass. Newly designed engine covers made of magnesium feature an advanced surface structure in order to reduce the wear caused by the rider’s boots.
Clutch – The highly compact CSS clutch (Coil Spring Steel) features a weight reduced, wear-free steel basket, and now seven instead of eight clutch plates, which are extremely heat resistant due to their steel carrier discs. In addition, a reworked inner hub and a pressure plate guarantee a better oil supply along with even better cooling of the clutch. A smaller master cylinder diameter of the Brembo hydraulic clutch system provides easier and precise modulation.
Transmission –The new engine is fitted with an all-new and weight reduced, five-speed gearbox. It features the same gear ratio as the previous model, but has wider gear sprockets, featuring a special surface treatment on the 2nd, 3rd and 4th gears for improved reliability. One of the new and special features on the bike is an advanced “NO-DIRT” gear lever design, which prevents dirt from blocking the joint of the lever and guarantees a safe activation of the transmission.
Engine management system – The completely reworked Keihin Engine Management System, with electronic fuel injection, features an all-new 44 mm throttle body, which provides a spontaneous response and maximum performance thanks to a revolutionary injector position. The new ECU (Engine Control Unit) includes a launch control for more efficient starts with the provision of different maps according to the gear sensor selection. In addition, the rider can activate an optional map for a different power delivery via the map select switch on the handlebar.
