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KTM 250 EXC-F 2018:A recipe for success

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Fill an agile, state-of-the-art chassis with an engine delivering class-leading power and torque. Then dress it with top class components, ensuring that the new 4-stroke maintains its edge over the competition. The result is a READY TO RACE dual sport suitable for amateur explorers, while still satisfying the pros. Eat that, adversaries.

Bodywork

KTM R&D, KISKA Design and the factory racers had their say

in shaping the plastics with one goal: complete harmony

between rider and bike. Perfect ergonomics and contact

points provide maximum comfort in movement on the EXC-F.

The I-beam structures of the front and rear fenders guarantee

maximum stability and a low weight thanks to well thought-out

construction and mounting. They also stay cleaner for longer.

Clever brake hose routing on the front number plate

prevents wear and tear.

Graphics

New graphics convey the READY TO RACE character of

the 2018 KTM EXC-F model line.

 

Engine

The light and compact KTM 250 EXC-F engine delivers class-leading

torque and power over the entire rev range. The architecture

with an optimized shaft configuration makes for excellent mass

centralization and effortless rideability, at only 27.6kg. And that’s

including the comfort of an E-starter. The power curve reaches for the

sky over the entire length of the rev range, begging for another

gear at 12,800rpm. This makes the new KTM 250 EXC-F brilliantly

suited to both amateur riders as to pros at the peak of their ability.

And it’s Euro IV homologated, so the planet will love you for it.

Cylinder head

The centerpiece of the compact DOHC engine is this cutting-edge

cylinder head. It features light, dual overhead camshafts with

friction-optimized cam followers boasting a hard DLC coating.

Four lightweight titanium valves and high-flow ports maximize the

flow rate for an optimal power band and outstanding performance

across the seemingly endless rev range of 12,800rpm. Two

lateral stays allow an efficient fixation of the engine to

the frame and reduce vibration.

 

Crankshaft

The KTM 250 EXC-F’s crankshaft utilizes a short connecting rod,

making for an overall compact and lightweight engine with a

snappy power delivery. A plain big (bottom) end bearing with two

force-fitted bearing shells runs directly on the crank pin. This

design is a must for the extremely high engine speeds and the

unrivaled power of this 250cc engine while also enhancing the engine’s

durability for long crankshaft service intervals

 

E-Starter

The KTM 250 EXC-F is fitted with a unique E-starter as standard,

which is a clear advantage when it comes to crunch

time in the heat of battle. A strong starter motor made

by Mitsuba will fire time and time again at the push of a button.

Even under extreme conditions, thanks to its more heat resistant O-ring.

 

Transmission

The engine is fitted with a precise 6-speed Enduro transmission,

with solid shift engagement thanks to a special low-friction coating

on the shift forks. An advanced ´No Dirt´ gear shift lever design

prevents mud or dirt build-up in the joint for trouble-free rides.

All KTM 4-stroke engines are fitted with a gear position sensor

that syncs the power curve to each gear. In MY18, the transmission

shaft gets a new C4 bearing that has a bigger overlap in the case.

This means reliability even under extremely hard conditions.

Think GP-level riding. In knee-deep sand.

 

Crankcases and engine covers

The design of the die-cast engine crankcases allows for a centralized

shaft configuration, moving the crankshaft close to the bike’s

center of gravity. All hail mass-centralization! The engine covers feature

an advanced surface structure to reduce the wear caused by

the rider’s boots.

 

Balancer shaft

To balance the mass forces, the engine uses a multifunctional

balancer shaft that also drives the water pump and timing chain.

 

Engine management system

The state-of-the-art Keihin engine management system with

electronic fuel injection features a 42mm throttle body. Thanks

to its unique injector position, the engine’s response gives

a whole new meaning to the word ‘instantaneous’. Separate

circuits for cold-starting and idle make on-site adjustments

easy. Push the throttle back when the engine is warmed

up and the cold start mode disengages.

 

Clutch

The KTM 250 EXC-F employs the KTM-developed DDS clutch

(damped diaphragm steel) with a wear-free steel basket

and extremely heat resistant clutch plates and new, nitrated

steel liners. This clever design employs a diaphragm spring

instead of the usual coil springs, making for considerably easier

clutch action. A diaphragm spring also leaves sufficient space for a

damping system to be integrated into the clutch hub. The goal

is traction, but durability is as well. Light operation and

telepathic amounts of control are standard with this

hydraulic Brembo actuated clutch.

 

Frame

The high-tech, lightweight chrome-moly steel frame has a knack for

easy handling, outlandish rideability, precise cornering and

excellent stability. You can also count on high torsional

rigidity and low longitudinal stiffness. This results in better

absorption of the energy created from the front and rear

suspension sucking up jumps and bumps. In short: more

comfort and less rider fatigue. Laterally attached, lightweight

engine head stays (the connection between cylinder head and frame)

contribute to a reduced vibration level. Two threaded inserts

in the lower cradle tubes allow for safe fixation of an

optional skid plate. The engineers could pull off all that, while

making their frame a big fat kilogram lighter than that of the

lightest competitor on the market. In addition, it is easier to maintain,

easier to work on and supplies more space for the tank

and other components. The bike also features an extra-light

subframe made of stable aluminum profiles, which tiptoes

the scales at less than 900g.

 

Footpegs

Sophisticated ´No Dirt´ footpegs prevent jamming up of the pegs,

even when digging in deep ruts. The pegs on the EXC models

are 6mm higher than the ones used on SX models, which benefits

ground clearance. But you can swap them at will.

 

Swingarm

This state-of-the-art swingarm allows for an optimized mounting

position of the PDS shock absorber, providing more

progressive action. Furthermore, the cast aluminum design

guarantees lower weight and a perfect flex behavior. The single-component

casting process also eliminates any inconsistencies and weak points.

 

Front suspension

The WP Xplor 48 upside-down fork is a split fork developed by

WP in close collaboration with KTM. It is fitted with a spring

on both sides but features separated functions for each fork

leg: compression damping is fitted on the left side, while rebound

is on the right. The forks can easily be adjusted for compression and

rebound with the twist of a dial on the top of the forks. New

outer fork tubes and a reworked setting make for more sensitivity,

improved damping behavior and a reduced weight. In addition,

a sealed hydro-stop guarantees excellent resistance to bottoming-out.

Due to high-quality materials and a state-of-the-art production

process, the new WP Xplor 48 fork – with approx. 300mm of travel – has

outstanding response and damping characteristics. A comfortable preload

adjuster can be retrofitted and allows for a simple spring preload

setting in three steps without tools (standard, +3mm, +6mm).

 

Rear suspension

The PDS is kind of a KTM trademark where the shock absorber is

directly connected to the upper side of the swingarm. This

setup boasts the best possible mounting geometry and

provides amazingly progressive damping. The shock absorber is

mounted close to the centerline, which means nearly

symmetrical loads for the swingarm and frame and more space

for the exhaust system. A second piston works together

with a closed cup (instead of a needle) towards the end of the stroke

and is supported by a progressive shock spring for exceptional

bottoming resistance. Various machined and anodized

components and a distinctive WP color trim make this a valuable,

high-end product compared to the less refined shock

absorbers of the competition.

 

Brakes

You can’t brake any harder, better, faster or stronger. High-tech

Brembo calipers are combined with lightweight Wave

brake discs. The steel-flex front brake hose has efficient protection

and there’s an integrated channel for the speedometer cable.

First you outrun them, then you outbrake them.

 

Handlebar

KTM engineers know how to handle handlebars. This tapered unit,

made of high-strength aluminum by NEKEN, features a throttle

assembly with a robust aluminum body and easy free-play

adjustment. An ODI volcanized grip sits on the right, while

on the left side of the bar a comfortable ODI lock-on grip

requires no glue or wire to secure it. You can retrofit two interchangeable

throttle cams, for different response characteristics to suit your

specific needs. With an optional map select switch you can select

an alternative power characteristic and activate the unique

traction control, a major benefit under wet riding conditions.

 

Triple clamp

The EXC-Fs are fitted with forged triple clamps with an

offset of 22mm, ensuring a solid grip of the fork and

precise handling. The handlebar is adjustable forwards

and backwards over 4 positions, so the EXC-F will fit

you like your favorite gloves.

 

Air filter box

The air filter box design offers maximum protection of the air

filter against soiling, while ensuring maximum airflow in a

quiet way. The large Twin Air filter is mounted in a stiff cage,

which at the same time holds the system in place. This

design is so simple; you can pop a fresh one in with

a face full of mud – without tools and in seconds.

 

Fuel tank

The lightweight polyethylene tank has a capacity of 8.5 liters.

You will always be able to see how much fuel remains at

a glance, thanks to the see-through plastic. By pushing the orange

release button in the center of the fuel tank cap, the bayonet

mechanism makes refueling quick and easy. It is fitted with an

integrated fuel pump system and a fuel level sensor. Additionally,

the fuel line features a 90° connector to the tank for better

protection against damage.

 

Exhaust system

Noise limits are a real challenge for every manufacturer. Therefore,

KTM has put a lot of effort into the development of its

exhaust systems. All 4-strokes are fitted with a short  high-end

aluminum muffler, mounted as close to the engine as possible.

This means more power, extra mass centralization and better rideability.

An advanced internal design reduces the noise sufficiently to sit

safely below the noise limit, while still providing the engine response

and performance that is expected from a KTM.

 

Wheels

The EXC-F’s wheels feature lightweight, CNC machined hubs

and high-end Giant rims guaranteeing maximum stability at

minimum weight. The wheels are fitted with MAXXIS tires – perfect

for surefooted performance off-road and stability on-road.

 

Battery & Wiring harness

A strong lithium ion battery breathes life into the engine

and contributes to low vehicle weight. The lightweight battery

and wiring harness are centralized in a compartment above

the air filter box, allowing the mechanic to remove the subframe

without getting in conflict with the electronics.

A happy mechanic is a good mechanic.

 

Cooling system

KTM’s proven cooling system routes the coolant from the cylinder

head through the frame triangle, directly to aluminum

radiators made by WP. Thanks to flow optimized internal circulation

and CFD-calculated ventilation, the system is superbly efficient.

In addition, new radiator protections improve heat dissipation.

Especially in the mud. They are also integrated into

the front part of the shrouds to protect the radiators in a crash.

 

 

 

 

 

 

 

TECHNICAL DETAILS

ENGINE

Design 1-cylinder 4-stroke engine
Displacement 249.91 cm³
Bore 78 mm
Stroke 52.3 mm
Starting Electric starter
Transmission 6 speed
Primary ratio 24:73
Secondary ratio 14:52
Clutch Wet, DDS multi-disc clutch, Brembo hydraulics
Ignition system Keihin EMS

 

CHASSIS

Frame design Chrome-molybdenum steel central-tube frame
Rear suspension WP Xplor PDS shock absorber
Suspension travel front 300 mm
Suspension travel rear 310 mm
Front - Rear Brake system Disc brakes
Brake discs - diameter Front 260 mm
Brake discs - diameter Rear 220 mm
Steering head angle 63.5°
Wheel base 1482±10 mm
Ground clearance (unloaded) 355 mm
Seat height (unloaded) 960 mm
Total fuel tank capacity approx. 8.5 l
Weight without fuel approx. 103 kg
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