photos: a. barbanti, p. friedl, h. mitterbauer, ktm .: 3 ... · photos: a. barbanti, p. friedl, h....

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

www.ktm.com

ART.

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12.3

57GB

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KTM

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LEGAL DISCLAIMERShould not be emulated. The riders illustrated are professional motorcycle riders. The photos were taken on a closed racing circuits or closed roads. KTM draws to the attention of all motorcycle riders that they should abide by all traffic laws and regulations, that they should wear the recommended pro-tective clothing and always ride in a responsible way.

The motorcycles advertised in this folder are only suitable for usein normal traffic in the homologated version.

When purchasing a motorcycle, it is necessary to clearly observe all safety aspects and appropriate warnings. The motorcycles illustrated are in part equipped with extras that are subject to additional costs. All information concerning delivery, appearance, performance and weights and measurements of the vehicles comply with KTM’s sales program in Austria at the time of printing and all information is supplied without obligation and may be subject to alteration at any time. Please note that model specifications can be different from country to country.

© 2011, KTM-Sportmotorcycle AG

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trailblazer

For 43 years now, KTM has consistently been taking on competitors in the top enduro competition classes. That means 43 years of constant development and continuous improvement of a concept tried and tested in countless competitions. This is the tradition that KTM is breaking from with the new EXC model range. KTM is taking 2 steps in one. The 2012 EXC generation is not simply an improvement on the previous models; it is a techni-cal masterpiece, redesigned from scratch that sets new standards. Revolution rather than evolution.

WCeNDUrO

• johnny aubert

PASSION

brOtHerS–iN–arMSThousands of passionate KTM enduro fans all over the world

have helped KTM to reach the prime position in this motor-cycle segment. Thanks to their experience and input, today KTM is able to build the best enduro motorcycles that can be bought on this planet. Two good reasons to decide in favour of a KTM EXC 2012: being part of the largest and most experienced offroad community in the world, fully aware that you’re sitting on the best enduro bike of all time.

eNDUrO

brOtHerS–iN–arMS

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eNDUrO RACING

FerveNtcOMraDeS

Our factory riders are also an indispensable part of this community. They test our bikes, year in year out, in races around the globe. Unrelenting and uncompro-mising. And long before we place them in the hands of our customers. And so it’s no coincidence that our production motorcycles are good enough to win races with. And we mean every race. Simply “Ready to Race”.

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New eNgiNeS

New FraMeNew plaSticS

• new 4-stroke engine generation with EFI• further development of the tried and tested 2-stroke

• with new PDS suspension

• sportier ergonomics

• New enduro benchmark • Ultimate riding fun• Incomparable agility

Attack the E2 Class! This bike will take the 450cc class by storm, all down to its incomparable lightness, the easy-to- control, high-performance engine and a completely new chassis with improved PDS suspension – a combination that makes the competition look a little long in the tooth. Last season’s magnificent MX successes suggest that we will achieve a similar result in the Enduro WC.

• Top quality chassisThe completely new bodywork with extremely slim seat and spoiler line lets machine and rider fuse into one. With a flat seat contour for maximum freedom of movement, deep handlebar offset and ideal ergonomics. There has never been more direct contact with the bike or more response to the slightest footrest or hip pressure.

bODYwOrK

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• Top quality chassis

• swingarmLighter, with new geometry and stunningly beautiful: the aluminium swingarm cast in a single piece. The sophisticated casting process provides unlimited geometric options – the swingarm can be laid out precisely in line with the designers requirements. One pleasant side effect: nothing can break the weld seams as they are nowhere to be found.

• frameAdvanced engineering: one of the lightest and most stable frame designs ever. Manufactured from high-quality chrome-molybdenum with wider profiles in the front frame triangle. This leads to greater lateral stiffness and with that better cornering safety and manoeuvrability. By contrast, stiffness has been reduced in the longitudinal direction – shocks from the rear wheel are absorbed elastically.

• PDS suspensionThere could be nothing better for enduro use: low weight, low maintenance and shock absorber replacement in a matter of seconds. The greatest benefit: more ground clearance compared to a linkage system. Where nothing protrudes below the swingarm, nothing can be damaged by stones or rock ledges.The new PDS monoshock has independent, fully adjustable rebound and high / low-speed compression damping. 7 mm more length and a flatter installation position provide even higher progression. The setting has been perfectly tuned to the new chassis.

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eNgiNe

DOHC cylinder head

Precision engine construction: four titanium valves are opened by twin overhead camshafts, the 8 g super-light cam followers are DLC-coated. This makes speeds of up to 12,000 rpm possible.

• Powerful engine characteristics• Extremely compact• Wide rev range

The engine management system from Keihin with electronic fuel injection and 42 mm throttle body ensures powerful responsiveness across a very broad rev range. Very smooth, very even, very efficient – a new dimension in enduro rideability. Standard equipment: electronic cold-start enrichment and automatic adaptation to temperature and altitude conditions. Reliable energy provision is taken care of by the powerful, oil-cooled, 196 W alternator. With an optional map-select switch and the user-setting tool (PowerParts), additional engine characteristics can be activated at the press of a button and the ignition and injection mapping can be individually adapted on a laptop via a USB interface.

Innovative: single-piece, ma-chined outer clutch hub without rivets featuring lining disks on slim steel carriers. The design guarantees maximum durability at the same time as a very flat construction. Pre-tensioning by means of a central spring washer. Without the conventional conical springs, there’s enough space for an integrated, transmission-friendly back-damping system. Standard equipment: hydraulic clutch actuation from Brembo. (see page 16).

CLUTCH

As standard with both kick and electric starters. The electric starter drive is integrated in the ignition cover and designed to be very small and compact. Those who prefer it can convert to pure kickstart operation. This saves an extra 1500 g for weight purists.

Electric starter

Engine management

First Oil Filling for all KTM Engines.

The completely new 350 cc power unit is comparable with nothing ever seen before. It is neither a small 450 nor a “bored out” 250; it has a character completely of its own. The primary reason for this is ab-solutely minimal moving masses. The engine therefore runs extreme-ly quickly in the rev range where most power is generated and impresses with unprecedented playful handling. Very mellow from low down and a real beast at higher engine speeds. You need to try it yourself to see how that feels.

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airboxQuality made in Austria: new silencer with a voluminous profile ensures compliance with future noise limits without compro-mising performance.

BREMBO system as standard, with lightweight wave brake discs. Floating, twin-piston brake caliper at the front and single-piston, floating brake caliper at the rear. Consistent application in all conditions, minimum effort, maximum braking performance.

Excel high-end rims in scratch-resistant silver featuring CNC-machined hubs, spokes with a fine zinc/nickel coating and highly stable aluminium spoke nipples. The overall package is therefore the lightest that money can buy.

Integrated coolant conduction from the cylinder head through the frame triangle directly to the radiators. This design with no external hoses facilitates simple radiator installation and increases air flow through the radiator. Together with optimised coolant flow, this lowers the temperature by up to 5° C.

WP Competition Race Tech: fully adjustable 48 mm upside-down forks with settings perfectly tuned to the new frame concept. The new SKF seal rings and an improved teflon coating on the slide bushes mean greater durability and optimum slid-ing behaviour.

We tinkered around with the new airbox to ensure only the important elements get through: maximum air, but minimum dust and spray.Replacement of the twin-air filter takes approx. 15 seconds, without any tools. It may surprise a few you, but at KTM that’s standard.

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• Sporty ergonomics• Playful handling• Top quality chassis

No other bike has won more world championship titles in the E1 class than the KTM 250 EXC-F. For the new season, it features revolutionary new bodywork, more power and a redesigned injection system.

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enginemangement

AlternatoreNgiNeConsistently refined in many details, the powerful 250 EXC-F power unit profits primarily from the new performance characteristics of the injection system. To ensure a reliable supply of energy to

the new fuel injection system, a more powerful 196 W alternator has been employed. The engine

case has been modified in such a way that the alternator runs in the oil bath and is therefore

permanently cooled.

For aficionados: 4 extra-lightweight tita-nium valves, twin overhead camshafts, DLC-coated cam followers weighing only 8g, engine speeds of up to 13,000 rpm. The intake port designed especially for the injection system with 10 % greater gas flow provides even more power.

Reliable lubrication, even when sub-jected to extreme use: Just like the larger engines, the new 250 EXC-F unit also has a common oil circuit equipped with two oil pumps.

The newly developed engine management system for the EXC 4-stroke models has the greatest impact on the performance characteristics of the small 250 cc displacement unit. The spontaneous and strong power development is perceptibly more linear and much more efficiently applied, even for hobby riders. Engine misfir-ing on opening up the throttle too quickly and time-con-suming jetting are from now on a thing of the past. The system has all the features of the 350 EXC-F.

Electric starter

The 250 EXC-F engine is equipped as before with both kick and electric starters. A new addition is the electric starter drive integrated in the ignition cover. It is now possible to convert to pure kickstart operation with a new ignition cover and save approx. 1.5 kg in the process.

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• Top quality chassis• Easy handling• Unrivalled weight

The 450 EXC has been the undisputed top dog in the top tier for many years now and is always one step ahead. But that was yes-terday. Now we have taken 2 steps further: New engine generation featuring elec-tronic fuel injection, less weight, more efficiently convertible power, revolu-tionary new bodywork. KTM 450 EXC Generation 2012: the advantage has never been greater.

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eNgiNe • Leading performance• Controllable power• Extremely lightweight, compact package

Engine case Oil

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The previous KTM engines with 450 and 510 cc displacement were the reference in their class. The newly developed engine generation is superior to them both in every respect: new SOHC cylinder head, new cylinder, new ducts, new combustion chamber, new camshaft, new forged pistons, new piston rings, new die-cast engine case, new crankshaft, new oil circuit, new clutch, new injection system, lighter, more compact, more efficient performance. And those are only the most significant points.

Groundbreaking power, direct responsiveness, homogeneous performance: in conjunction with the new engines, the new engine manage-ment system from Keihin provides for perfect performance characteristics in enduro use. The features: 42 mm throttle valve sensor, electronic cold-start enrichment, automatic adaptation to the respective temperature and altitude condi-tions. The oil-cooled 196 W alternator ensures reliable energy provision; the closed-loop lambda control reduces emission levels in the homologat-ed condition. Optionally with map-select switch and the user-setting tool (PowerParts).

A weight saving of over 2 kg in the engine alone is a clear declaration of intent: The most signifi-cant contribution to this is made by the meticulous-ly designed engine case, which is manufactured for the first time in a die-casting process. Also new is the elastic and, at the same time, high-strength aluminium alloy that provides the housing with the best possible protection from mechanical damage. The balancer shaft is positioned laterally and simultaneously drives the water pump, hence facilitating a slimmer and shorter design.

All 4-stroke models have a common oil circuit with separate pres-sure and suction pumps. The pressure pump guarantees reliable pressurised lubrication of crankshaft, piston, balancer shaft and valve controls. It also ensures cooling of the ignition and lubrica-tion of the clutch. A suction pump draws oil from the crankcase and uses it to lubricate the transmission. This creates a slight vacuum in the crankcase, which has the positive “side effect” of increasing engine performance.

Engine management

clutchNew clutch system featuring smooth-shifting, hydraulic clutch actuation from Brembo. Innovative, machined, steel outer clutch hub without rivets. The clutch

package is pre-tensioned by means of a central spring washer. This facilitates a very flat con-struction with integrated back-damping, which ensures maximum traction in every situation and conserves the transmission.

SOHC cylinder head

The new SOHC cylinder head has a completely redesigned combustion chamber and flow-optimised ducts. By means of rocker arms, the overhead camshaft opens 4 valves that are made of high-quality titanium on the intake side. The overall concept has been perfectly tuned to the new injection system.

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SOHC cylinder head

• Undisputed benchmark• Super-slim ergonomics• Agile chassis

The big E3 class (over 500 cc 4-stroke) has been around in the Enduro World Championship since 2004. KTM has won it. Every time. Without exception. 7 times in succession. The motor-cycle in the E3 class for the new season is the completely new KTM 500 EXC.

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eNDUrO

Erzberg Hare Scramble, Novemberkasan, Roof of Africa, Hell’s Gate, The Tough One, Red Bull Romaniacs – blood, sweat and tears. In the world’s toughest Enduro races, every single kilogramme feels like 5. One good reason for us to stick to the 2-stroke engine with its conceptual benefits and to consistently refine it further.

beware: Never go to a gunfight with a knife.

EXTREME

twOStrOKe

EXPERIENCEeNDUrO

eNDUrO eXtreMe

Unique power-to-weight ratio, incomparably playful handling, simple construc-tion with low acquisition and maintenance costs - there are plenty of good reasons why we have refined our 2-stroke models for the new model generation so comprehensive-ly. KTM 2-Stroke Generation 2012: 4 different displace-ments with completely new bodywork and even more power. There has never been a better argument for two stroke!

Many good reasons more: Two Stroke Generation 2012

• Playful handling• Sporty ergonomics• Top quality chassis

The Erzberg serial winner and serious opponent for the 4-stroke meteors in the Enduro World Championship. Outstanding power-to-weight ratio, with electric starter and 6-speed transmission as standard. For 2012, with completely new bodywork and even more performance.

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MOtOrThese engines show what’s possible when the 2-stroke principle is taken seriously and done properly. Where others have long since given up, KTM is raising the bar even higher. Year after year.

• Minimal dimensions• Unrivalled performance• Spontaneous power development

Electric starter

Far in advance: KTM was the first manufacturer to equip 2-stroke race enduro bikes with kick and electric starters as standard. With its patented placement in a longitudinal direction above the ignition, the compact starter system is pro-tected and provides a decisive advantage in hard offroad use.

By opening and closing a plug connection, the choice can be made between the standard ignition curve and a softer version. Those who prefer even greater convenience can buy a switch from the PowerParts range.

Never miss a gear again in really tricky offroad sections: a close-ratio 6-speed transmission comes as standard.

CylinderIdeal for enduro use: plenty of power from very low down and controllable rideability throughout the entire rev range. The response of the exhaust control system can be individually tuned by means of different springs. This way, everyone can very easily vary the power development of their EXC between “soft” and “aggressive” in a matter of seconds.The new cylinder on the 300 EXC and the new reed valve block on the 250 EXC and 300 EXC mean noticeably more accel-eration and more homogeneous power development.

250/300 22|23

New for 2012: chassis and bodywork, airbox, flow-opti-mised intake snorkel, reed valve block and cylinder. Still the same addictive sound.

MODEL

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300EXC

Feels like a mountain bike. Until you twist the throttle. Then it feels different. Better. Much better. For 2012, with greater peak power, new airbox, new intake snorkel and new exhaust expansion chamber. Oh, and the kickstarter is now 80g lighter. Yes, that does make a difference.

Not a displacement class for the Enduro WC, but the displacement class for straightfor-ward riding fun. If you look at the level of demand for the 200 EXC, it appears that for plenty of people it’s exactly what they want.

MODEL EXC200

eXcSIXDAYS

The special model for the world’s greatest Enduro race, the “International Six Days Enduro”. More than 500 riders from over 30 nations fight for the world championship title over 6 days. For the 2011 season, the legendary marathon will be held in the forests around Kotika-Hamina in Finland. The challenging, sandy terrain will demand every last drop from man and machine. More than half the starters trust in KTM, because they know that at least the machine will hold out. With good reason.

eXcSIXDAYS

• low weight• exclusive Six Days graphics• high quality equipment

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SixDays Models MY 20122-stroke: 125 exc, 250 exc, 300 exc4-stroke: 250 exc-f, 350 exc-f, 450 exc, 500 exc

“Ready to Race”. 7 Six Days models with all the extras you need for the world’s greatest Enduro race. Everything anyone could wish for is included in the standard package.

special equipment

Rear sprocket

Fork

Exhaust protection Not because it looks so good; because it protects the exhaust expansion chamber so effectively: carbon protector on all 2-stroke models.

Not because it looks good; because it optimises sliding behav-iour: CNC-machined triple clamp.

Not because it looks so good; but because it withstands everything: 2-component rear sprocket with extra strong steel outer ring and aluminium inner.

• CNC-machined triple clamps, orange anodised• Camel SXS seat with greater seating comfort• High-strength plastic engine guard• Complete rear brake disc with brake disc protector• Quick-change brake pad securing bolts at the rear• Wheel spindle at the front• 2-component rear sprocket with steel outer ring and aluminium inner ring• Radiator fan for all four-stroke models• Map-select switch on handlebars for changing the engine characteristics (250/300 EXC)• Carbon exhaust protector for all two-stroke models• Exhaust silencer with SixDays anthracite anodising• Frame with orange factory team coating• Black anodised aluminium handlebar

SIXDAYSeXc

Made in Austria – by riders for riders. Designers without racing experience are a rarity at KTM. That’s why every KTM follows the logic of the race. So that you never tire, so that the ergonomics fit perfectly, so that no additional ballast is carried, so that every maintenance task is particularly easy, so that they reliably with-stand the hardest of tests, where they reveal their decisive advan-tage.

MaDe IN AUSTRIA

Customise your bike with original KTM PowerParts. Ask your dealer for a catalogue and visit www.ktm.com for all the latest news. SXS Slip-On

Factory Silencer

seat X

Map Switch

pOwerPARTS

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Customise your style with original KTM PowerWear. Ask your dealer for a catalogue and visit www.ktm.com for all the latest news.

pOwerWEAR

gravity-fx helmet

tech 8 boot

KTM neck brace adv II

FLUX SHIRT 12

racing progoggles

training camps for all brandswww.ktmcamps.com

The better you can do something, the more fun it is. With KTM Adventure Tours, everybody has more fun: whether you’re male or female, a beginner or an ambitious expert. First-class instructors, perfect organisa-tion and fantastic locations in Italy turn every KTM Adven-ture Tour into an unforgetta-ble experience. Details on all tours can be found at www.ktmadventuretours.com.

We live “Ready to Race”. And we show you how to ride “Ready to Race” too. At the new KTM Race Camps. The

first and only professional racing academy. At the best locations, with professional trainers and progressively

designed content for the rider of tomorrow – you. Welcome to the KTM Race Camps!

First Oil Filling for all KTM Engines.

aDveNtUre TOURS

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DATA

ENGINE ENGINE TyPE DISPLACEMENT BORE / STROKE COMPRESSION RATIO STARTER / BATTERy TRANSMISSION CARBuRETOR CONTROL LuBRICATION GEAR RATIOS TRANSMISSION OIL PRIMARy RATIO FINAL DRIvE COOLING CLuTCH IGNITION

CHASSIS FRAME SuBFRAME HANDLEBAR FRONT SuSPENSION REAR SuSPENSION SuSPENSION TRAvEL FRONT / REAR FRONT / REAR BRAKES FRONT / REAR RIMS FRONT / REAR TIRES CHAIN SILENCER STEERING HEAD ANGLE WHEEL BASE GROuND CLEARANCE SEAT HEIGHT TANK CAPACITy, APPROx. WEIGHT, WITHOuT FuEL, APPROx.

Single cylinder, 2-stroke249 cc66.4 / 72 mm–Kick- and electric starter / 12 V, 3 Ah6 gearsKeihin PWK 36S AGPressure-controlled exhaust valveMixture oil lubrication 1 : 6014 : 32, 16 : 26, 20 : 25, 22 : 23, 25 : 22, 26 : 20Motorex, 15W-5026 : 7214 : 50 (13 : 50)Liquid coolingWet multi-disc clutch, Brembo hydraulicsKokusan

Central double-cradle-type 25CrMo4AluminiumNeken, Aluminium Ø 28 / 22 mmWP-USD Ø 48 mmWP-PDS shock absorber300 / 335 mmDisc brake Ø 260 / 220 mm1.60 x 21"; 2.15 x 18" Excel90 / 90-21"; 140 / 80-18"X-Ring 5/8 x 1/4"Aluminium63.5°1,482 ± 10 mm355 mm960 mm9.5 l102.9 kg

Single cylinder, 2-stroke193 cc64 / 60 mm–Kickstarter6 gearsKeihin PWK 36S AGPressure-controlled exhaust valveMixture oil lubrication 1 : 6012 : 33, 15 : 31, 17 : 28, 19 : 26, 17 : 19, 22 : 20Motorex, 15W-5023 : 7314 : 45Liquid coolingWet multi-disc clutch, Magura hydraulicsKokusan

Central double-cradle-type 25CrMo4AluminiumNeken, Aluminium Ø 28 / 22 mmWP-USD Ø 48 mmWP-PDS shock absorber300 / 335 mmDisc brake Ø 260 / 220 mm1.60 x 21"; 2.15 x 18" Excel90 / 90-21"; 120 / 90-18"X-Ring 5/8 x 1/4"Aluminium63.5°1,471 ± 10 mm355 mm960 mm9.5 l96 kg

Single cylinder, 2-stroke124.8 cc54 / 54.5 mm–Kickstarter6 gearsKeihin PWK 36S AGPressure-controlled exhaust valveMixture oil lubrication 1 : 6012 : 33, 15 : 31, 17 : 28, 19 : 26, 21 : 25, 20 : 20Motorex, 15W-5023 : 7314 : 50 (13 : 50)Liquid coolingWet multi-disc clutch, Magura hydraulicsKokusan


Single cylinder, 2-stroke293.2 cc72 / 72 mm–Kick- and electric starter / 12 V, 3 Ah6 gearsKeihin PWK 36S AGPressure-controlled exhaust valveMixture oil lubrication 1 : 6014 : 32, 16 : 26, 20 : 25, 22 : 23, 25 : 22, 26 : 20Motorex, 15W-5026 : 7214 : 50 (13 : 50)Liquid coolingWet multi-disc clutch, Brembo hydraulicsKokusan


* Also available as Six Days models!

2S MODEL MODEL MODEL MODEL

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250EXC

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DATA

Single cylinder, 4-stroke349.7 cc88 / 57.5 mm12.3 : 1Kick- and electric starter / 12 V, 4 Ah6 gearsKeihin EFI, flow restrictor 42 mm4 V / DOHC with finger followersPressure lubrication with 2 oil pumps14 : 32, 16 : 26, 20 : 25, 22 : 23, 25 : 22, 26 : 20Motorex, SAE 10W-5024 : 7314 : 52 (13 : 52)Liquid coolingWet multi-disc clutch, Brembo hydraulicsKeihin EMS


ENGINE ENGINE TyPE DISPLACEMENT BORE / STROKE COMPRESSION RATIO STARTER / BATTERy TRANSMISSION CARBuRETOR CONTROL LuBRICATION GEAR RATIOS ENGINE OIL PRIMARy RATIO FINAL DRIvE COOLING CLuTCH IGNITION

CHASSIS FRAME SuBFRAME HANDLEBAR FRONT SuSPENSION REAR SuSPENSION SuSPENSION TRAvEL FRONT / REAR FRONT / REAR BRAKES FRONT / REAR RIMS FRONT / REAR TIRES CHAIN SILENCER STEERING HEAD ANGLE WHEEL BASE GROuND CLEARANCE SEAT HEIGHT TANK CAPACITy, APPROx. WEIGHT, WITHOuT FuEL, APPROx.

Single cylinder, 4-stroke449.3 cc95 / 63.4 mm11.8 : 1Kick- and electric starter / 12 V, 4 Ah6 gearsKeihin EFI, flow restrictor 42 mm4 V / OHC with rocker leversPressure lubrication with 2 oil pumps14 : 36, 17 : 32, 19 : 28, 22 : 26, 24 : 23, 26 : 21Motorex, SAE 10W-5032 : 7614 : 52 (13 : 52)Liquid coolingWet multi-disc clutch, Brembo hydraulicsKeihin EMS


Single cylinder, 4-stroke510.4 cc95 / 72 mm11.8 : 1Kick- and electric starter / 12 V, 4 Ah6 gearsKeihin EFI, flow restrictor 42 mm4 V / OHC with rocker leversPressure lubrication with 2 oil pumps14 : 36, 17 : 32, 19 : 28, 22 : 26, 24 : 23, 26 : 21Motorex, SAE 10W-5032 : 7614 : 50 (13 : 50)Liquid coolingWet multi-disc clutch, Brembo hydraulicsKeihin EMS


Single cylinder, 4-stroke248.6 cc76 / 54.8 mm13.2 : 1Kick- and electric starter / 12 V, 4 Ah6 gearsKeihin EFI, flow restrictor 42 mm4 V / DOHC with finger followersPressure lubrication with 2 oil pumps13 : 33, 17 : 33, 19 : 29, 23 : 28, 23 : 23, 26 : 22Motorex, SAE 10W-6022 : 6814 : 50 (13 : 50)Liquid coolingWet multi-disc clutch, Brembo hydraulicsKeihin EMS


* Also available as Six Days models!

4S MODEL MODEL MODEL MODEL

250EXC-F

450EXC

350EXC-F

500EXC

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* * **

photos: a. barbanti, p. friedl, h. mitterbauer, ktm .: 3 ... · photos: a. barbanti, p. friedl, h....

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