KTM 300 EXC TPI 2018:Revolutionary
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
New graphics convey the READY TO RACE character
of the 2018 KTM EXC model line.
KTM engineers just love dropping weight year after year. The result:
the 2018 KTM EXC models are the slimmest, lightest dirt bikes out there.
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.
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.
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.
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.
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.
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).
|Design||1-cylinder, 2-stroke engine|
|Starter||Kick and electric starter|
|Secondary gear ratio||14:50|
|Clutch||Wet, DDS multi-disc clutch, Brembo hydraulics|
|Frame Design||Chrome-molybdenum steel central-tube frame|
|WP Xplor PDS shock absorber|
|Suspension travel (front)||300 mm|
|Suspension travel (rear)||310 mm|
|Front brake||Disc brakes|
Rear brake disc diameter
Front brake disc diameter
|Wheel base||1482 ± 10 mm|
Steering head angle
|Seat height||960 mm|
Tank capacity (approx.)
|Weight READY TO RACE (without fuel)||103 kg|