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KTM 300 EXC TPI 2018:Revolutionary

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4-stroke rivals, beware: this tool might just be the sharpest in the shed. If you want torque by the bucket loads, a top-end to die for and a lightweight chassis ready to rise to any occasion, give this fuel-injected 300cc lightning bolt a go.

Engine

When it comes to optimal power-to-weight ratio and outstanding

Enduro specific performance the new KTM 300 EXC TPI engine

reigns supreme. It features an all-new TPI electronic fuel injection,

which will set a new benchmark in the offroad competition 2-stroke

segment. And thanks to its modern architecture including high-end

features such as the well protected E-starter, a new cylinder with

two injectors and power valve, a 6-speed Enduro transmission and a

hydraulically operated DDS clutch, the KTM 300 EXC TPI

machine will the best choice when the going gets real tough.

 

 

 

Cylinder

The new KTM 300 EXC TPI cylinder has a bore of 72mm

and is fitted with the sophisticated power valve, which provides

really smooth and controllable power characteristics. For the

EFI application the new cylinder features two lateral domes that

hold the fuel injectors supplying fuel into the rear transfer ports.

The downstream injection guarantees excellent atomization of

the fuel with the upstreaming air. Thus the loss of unburnt fuel

is reduced for less emissions, a more efficient combustion and

reduced fuel consumption. A little tube in the back of the cylinder

is connected with an intake pressure sensor, which supplies

pressure data to the control unit. Furthermore, it’s possible

to change the bike’s mood in seconds thanks to two supplied

power valve springs. Limitless settings for different

tracks and preferences are up for grabs.

 

 

 

Oil pump

Pre-mixing 2-stroke fuel is a thing of the past for KTM EXC

TPI owners. An electronic oil pump feeds oil from the oil tank

via the throttle body into the engine intake, and ensures a perfect

fuel-oil mix in all conditions and engine speeds. The system, which

reduces up to 50% of the smoke from the exhaust system over

previous models, is managed by the control unit based on the engine’s

revs and load measured by the TPS (throttle position sensor). The oil

capacity of approximately 0.7 liters is enough for 5-6 refills of

fuel, giving you more time to ride, less time measuring things out.

 

 

 

 

Crankcases

For optimal mass centralization the lightweight die-cast crankcases

hold the clutch shaft and the crankshaft in a high position close to

the center of gravity. Which is nice if you care about sweet handling.

In addition, it allows the implementation of a balancer shaft. So your

ride will be as relaxed as it is rapid. Plus, your new favorite engine will keep

looking as fresh as the day you bought it: the engine covers feature a

smart surface structure that reduce the wear caused by the rider’s boots.

 

 

 

Transmission

This 6-speed Enduro transmission features an Enduro-specific

wide-ratio specification and provides precise and easy shifting.

Keeping safety in mind, an advanced ´No Dirt´ gear shift lever design

prevents muck from blocking the joint. Because even

dirt lovers hate mud when it’s in the wrong places.

 

 

 

 

Balancer shaft

Say goodbye to numb feet and hands. This engine design allows

the implementation of a lateral balancer shaft in order to keep the

vibrations to a minimum. You know what that means:

more comfort, less fatigue, bigger smiles.

 

 

 

 

Clutch

The KTM 300 EXC TPI employs the KTM-developed DDS clutch

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

 

 


 

Exhaust system

This nickel-plated pipe is produced by WP Performance

Systems. It is taken over from the carburetor model and

designed for an optimal power band and maximal performance of

the engine. A modern 3D production process guarantees top precision

and reliability of the pipe, so this screamer is as tough as it is strong.

 

 

 

Throttle body

The TPI engine is fitted with a newly developed throttle body

made by Dell`Orto. It features a diameter of 39mm. The airflow

is regulated by a butterfly connected with a twin-cable throttle cam,

which is operated by a new handlebar throttle assembly. A throttle position

sensor provides airflow data to the control unit, while a bypass screw

allows the regulation of the idle speed. The cold start device also opens

a bypass supplying more air. Via an oil intake tube oil supplied from the

oil pump is mixed with the incoming air to lubricate

crankshaft bearings and cylinder/piston etc.

 

 

 

Generator

The TPI models are fitted with a stronger generator delivering

196 W (the same as their EXC 4-stroke brothers) to meet

the needs of the engine management system in terms of energy

supply. The new regulator mounted on the left side of the steering

head is taken over from the EXC-F models.

 

 


 

Engine management system

The engine management system (EMS) of the TPI models features

a new control unit located below the seat. The control unit determines

the ignition timing and the amount of fuel to inject is based on several

sensor readings such as intake and ambient air pressure, throttle position,

oil and water temperature. Thanks to altitude and temperature compensation

the rider does not need to worry about fiddling around with the jetting anymore.

 

 

 

 

Footpegs

Sophisticated ´No Dirt´ footpegs prevent smudging up the pegs,

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

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

clearance. But you can swap them at will.

 

 

 

Air filter box

The air filter box design offers maximum protection of the

air filter against soiling, while ensuring maximum airflow.

The EXC TPI models get a new intake snorkel designed for the new

throttle body while also hosting an air temperature sensor. The

large Twin Air air filter is mounted on a stiff cage, which at the

same time holds the system in place. This design is so simple,

you could still pop a fresh one in with a face full of mud.

Without tools. In seconds.

 

 

 

 

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.

 

 

 

 

Fuel tank

This is a lightweight polyethylene tank with a capacity of 9.25

liters. The EXC TPI models incorporate a new integrated fuel pump

system and an additional fuel level sensor so you’ll always know when

you’re running low on gas.

 

 

 

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. The additional KTM PowerParts radiator fan that

riders can add to this fuel injected 2-stroke is now regulated by

the control unit, no thermo switch is required anymore. 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.

 

 

 

 

Wheels

The EXC 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.

 

 

 

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. 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 model line.

 

 

 

 

Featherweight

KTM engineers just love dropping weight year after year. The result:

the 2018 KTM EXC models are the slimmest, lightest dirt bikes out there.

 

 

 

 

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. On the EXC TPI models

the upper frame tube features a slot where the oil filler cap is mounted,

which feeds the oil tank via a hose inside the frame tube. The bike also

features an extra-light subframe made of stable aluminum profiles,

which tiptoes the scales at less than 900g.

 

 

 

 

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.

 

 

 

Triple clamp

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 TPI will fit you like

your favorite gloves.

 

 

 

 

Brakes

You couldn’t brake any harder, better, faster or stronger.

These high-tech Brembo babies are combined with

lightweight Wave brake discs and are the ultimate solution

in braking technology. First you outrun them, then you outbrake them.

 

 

 

Swingarm

The cast aluminum design offers low weight and a perfect

flex behavior. The single-component casting process eliminates

any inconsistencies and inherent weak points created by welding.

It’s better looking too.

 

 

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).

 

 

 

 

TECHNICAL DETAILS

ENGINE

Design 1-cylinder, 2-stroke engine
Displacement 293.2 cm³
Bore 72 mm
Stroke 72 mm
Starter Kick and electric starter
Transmission 6-speed
Primary drive 26:73
Secondary gear ratio 14:50
Clutch Wet, DDS multi-disc clutch, Brembo hydraulics
EMS Synerject
   

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 brake Disc brakes

Rear brake disc diameter

220 mm

Front brake disc diameter

260 mm

Rear brake

Disc brake

Ground clearance

370 mm
Wheel base 1482 ± 10 mm

Steering head angle

63.5 °
Seat height 960 mm

Tank capacity (approx.)

9 l
Weight READY TO RACE (without fuel) 103 kg
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