Revolution: KTM EXC and EXC-F 2021 - a new generation of enduro
A completely new step has been taken by KTM in its approach to creating motorcycles for sports, in particular for motocross and enduro: in 2017, all KTM EXC and EXC-F models received a set of control electronics, traction control and became much safer, lighter and faster.
MOTOGONKI.RU, July 22, 2021 — In 2011, the Mattighofen plant concentrated on capturing the road segment of the European market and succeeded in this. Over the past 5-6 years, every year from two to five radically new products have been born in the model range, new buildings of the factory complex on Staleliteynaya Street in this small but world-famous Austrian town have been growing like mushrooms after rain; R&D has received its own building department, the KTM Racing division has its own home. Finally, KTM Factory Racing is preparing to enter MotoGP in 2021 as an official two-rider factory team, with plans to have a satellite team by 2018.
Does the video take a long time to load? Click here!
All these years, KTM has not forgotten about off-road. Although the successes of the world's KTM pilots in MXGP have not been so noticeable in the last couple of seasons, in enduro and rally raids, in particular at the Dakar rally marathon, the motorcycles created on the 5th production “special” line of Mattighofen had no competitors . From 1990 to 2015, the plant took a total of 110 world titles, and this year brought this figure to an even 111.
KTM EXC 250 (2017)
Not evolution, but revolution
It's time to return attention to the off-road area! The first sign of switching priorities is the new line of KTM EXC and EXC-F MY2017 enduro motorcycles, created literally from scratch.
KTM EXC 250 (2017)
KTM will have six new off-road motorcycles in its 2021 lineup, both 2-stroke and 4-stroke: KTM EXC 250 and 300 (2T), EXC-F 250, 350, 450 and 500 (4T).
Plus, each version of the motorcycle will also have a charged version - KTM Six Days Enduro in honor of the 6-day endurance race ISDE 6 Days Enduro, which has been held annually since 1913 and has been repeatedly conquered by KTM pilots. Each year, the model's graphics include the country where this historic race is held: the 2017 bike features "SPAIN" (Spain), so there is no confusion with previous versions!
KTM EXC 250 Six Days: in 2021 - this is Spain, in no way to be confused with other versions!
This version includes a full set of additional Power Parts tuning, a special memorable color scheme and is aimed at those who are going to use the motorcycle 100%. Moreover, the cost of the motorcycle ends up being much lower if you take the basic version and try to attach all this equipment to it separately, which should attract more customers.
I would like to immediately note that the youngest models with 125 cc engines. left the stage due to the fact that, well, there is no way to fit them into the new EURO4 environmental standards, which come into force on January 1, 2021 throughout the EU. One can only wonder how engineers from Austria managed to stay within these rules when introducing new products with 250 cc engines, especially 2T!
KTM EXC 250 (2017)
Key changes
Firstly, having achieved significant success in elite sports, KTM once again sets its sights on the amateur market. In 2015-2016, the first step in this direction was taken, when the company began to equip its motocross and enduro motorcycles with air forks, which are much more convenient to set up - for the majority of amateurs who do not have support teams. Secondly, ergonomics and design are aimed at reducing pilot effort during long-term operation in modes with a wide variety of loads. The seat has taken on a smoother shape and is 14mm lower front and rear; the linings have become narrower and more compact, the tank is easier to hold with your knees, and the engine covers have received a special coating that prevents abrasion from constant contact with the hard linings of powerful enduring motorcycle boots.
New No-Dirt pegs: 6 mm higher than on the KTM SX motocross; dirt cannot jam the mechanism
The footrests and pedals are all made in the No-Dirt concept, that is, they are not just self-cleaning, but are made in such a way that dirt cannot get into the bracket and block its mobility.
No-Dirt Footpegs: KTM EXC and EXC-F 2017
The third in a row, but the first in essence: the weight distribution has been changed, the mass centralization of the motorcycle has become an order of magnitude better, everything, literally everything has been made lighter, and the engines have become even more powerful. The EXC series motorcycles were already close to ideal in terms of power-to-weight ratio and overall layout, but the engineers managed to find new loopholes to rework literally every detail. In general, everything was created from scratch, and not with the aim of refining existing components.
KTM EXC: still more compact and lighter, even the battery is only 1 kg!
Even the battery is now a full kilogram lighter: the KTM EXC and EXC-F models use a Li-Ion battery of minimal weight, but powerful enough to start even the largest 500 cc engine after a long period of inactivity or when hot. But KTM says goodbye to kick starters on 4-stroke models: in stock, not a single model has that element for which the KTM abbreviation was mockingly deciphered “kick ten minutes.” But the Kickstarter Kit as an additional option can be purchased additionally and installed on the EXC-F 450 and 500 from September this year.
Well, the main thing, probably, was the introduction by KTM engineers of a full-fledged electronic traction control and launch support system, which has never happened before. More on this below.
KTM EXC 250 (2017)
Chassis
The frame of the KTM EXC and EXC-F was created, like everything else, from scratch and is significantly different from the previous version, even visually. The engine sits differently in it, which contributed to improved mass centralization and, therefore, easier handling. The engine mounting brackets are made of aluminum alloy, lightweight and help transmit less vibration to the frame. The new frame design provides 20% more torsional rigidity while providing 30% more flexibility to the overall chassis.
KTM EXC 250 (2017) without plastic and tank - chassis and engine
The key change is the new WP XPLOR 48 fork and XPLOR PDS shock. In total, both units provide a saving of 950g, making the chassis lighter by 2.5kg.
New fork stays WP XPLOR 48
The XPLOR 48 features a much simpler (no tools) adjustment of compression, rebound and preload. Rebound (red selector) is adjusted in the right chainstay, preload (white selector) in the left. The fork legs, like the shock absorber, have a progressive characteristic with a “hydrostop” function, which prevents a hard impact when the shock absorber is fully folded. The rear shock absorber is built using a linkless design, although it provides progression due to the internal design.
WP XPLOR PDS linkless progressive shock absorber design
By abandoning the lever system, which was retained on the KTM SX-series cross-country bikes, the factory solved one of the main problems - the issue of ground clearance, which becomes acute as soon as a motorcyclist tries to get over any obstacle, for example, a log. As soon as you put the motorcycle on its belly, the first thought was how to preserve the suspension arms - they are aluminum. Now this place is empty - climb to your health!
Engines
The power of the most popular 4-stroke KTM EXC-F engines is growing before our eyes every year, while their weight is also rapidly decreasing. If we draw analogies, then at the time of the birth of a new concept, for example, EXC-F 500 in 2000, this engine weighed 35 kg and produced only 50 hp, and the 2021 model weighs only 30 kg and now produces an incredible 65 hp. With. The KTM EXC-F 250 at its peak has become 2 hp more powerful than last year’s version. and reached 40 hp. and 28 Nm of torque; EXC-F 350 produces 48 hp/39.5 Nm.
KTM notes that although the EXC and SX engines are based on the same concept, in fact, they are completely incompatible, since most of the CPG and drive parts are different.
2021 Generation KTM EXC-F 250 and 350 4-Stroke Engines
The KTM EXC-F 250 and 350 are de facto the same engine, but with different cylinders, pistons and gear ratios. The 4-stroke engines received new injectors with 42 mm throttle bodies and new engine control units with a more powerful processor that takes into account not only the composition of the mixture, but also the speed and throttle position. The crankshaft, shorter connecting rod, crankcase, engine covers, a fundamentally different start and gearbox were designed from scratch.
2021 generation KTM EXC 250 and 300 2-stroke engines
The KTM EXC 250 and 300 received new MIKUNI carburetors instead of KEIHIN, which curtailed its development program and switched to injection systems. The old KEIHIN model was no longer satisfactory for the Austrian plant and could not ensure the precise operation to comply with EURO4. MIKUNI created a carburetor for KTM that fits perfectly into the 2021 kit. The engine is completely redesigned: there is also a new cylinder head, cylinder, power valve, crankshaft, starter, covers and gearbox, and also a new balancer shaft, which reduces vibrations on the steering wheel and footrest by almost half compared to models of previous years. Unlike 4T models, 2T motorcycles retain kick in their design.
Cool innovations
What cannot be found on an off-road motorcycle - a traction control system - now exists in nature, thanks to KTM, and it works perfectly!
When KTM introduced its SX range of motocross bikes in 2021, one of the big features was the ability to select ignition maps, as well as electronic Launch Control, a system that helps the rider get off to a smooth start from a standing start. Essentially, Launch Control limits the amount of torque and power that goes to the rear wheel, dosing it linearly so that the front wheel doesn't fly into the air when the throttle is wide open. When developing the 2021 EXC line, KTM engineers went further: using the algorithms embedded in Launch Control as a basis, they figured out how to make a working version of real traction control, but without resorting to installing additional speed sensors on the wheels, which is also prohibited regulations of international enduro competitions.
On the KTM EXC enduro, the mode switch and traction control can be placed on both the left and right
KTM Traction Control works on the principle of analyzing the linearity of the crankshaft rotation speed (RPM). The algorithm includes many variations of changes in dynamics, including jumping and overcoming various objects. When a clearly unplanned increase in speed occurs, the ECU gently changes the ignition timing, thereby smoothly but quickly limiting the power supply to the wheel. In KTM's press testing in early July, the number of crashes due to rear wheel spin and loss of track contact was significantly reduced to zero compared to trying to ride with TC off (yes, it's completely switchable, like on all KTMs). ). This is a big step towards amateur pilots and a help for beginners! Proriders may not enable TC or may disable it. In general, in the basic factory configuration this option is permanently enabled. To turn off the traction and also be able to choose between two piloting modes (“standard” and “aggressive”), you need to install a mode switch. In the Six Days version, this important option is already included in the package, so the motorcycle can be considered 100500% complete.
New radiator shape and fan for KTM EXC 250/350/450/500
Chips
Requests from customers and reviews from test pilots of specialized publications do not pass by the KTM R&D department. The 2017 model takes into account many wishes. First, KTM carried out a recall campaign, completely replacing the spokes and wheels on last year's models, which blew out on hard landings. The new model uses different spokes that can withstand heavy loads without adding weight.
Removing and installing the face on the KTM EXC 250? Clamp with clip: once and done!
Secondly, the plant now installs quick-release headlight “masks” on its enduro bikes: Alexey Kochalaevsky, a leading specialist at KTM Russia, demonstrated how you can remove and install back the entire “face” on a count of 1-2-3. KTM has also released an additional accessory for those who participate in night enduro racing - a “muzzle” with a powerful LED headlight, which provides three times more light with the same consumption. However, this accessory is certified “off-road only”, that is, in Europe it is not allowed on public roads due to too much light.
Now the speedometer cable is securely fixed and located next to the brake line: do not get caught, do not fray
Finally, a very nice innovation: the speedometer cable, an integral part of a road-ready enduro bike, is safely locked into the same tire as the brake line.
The speedometer cable and brake line are connected together and secured along the left stay: securely and without any chance of snagging from the side
Flexible tubes are fixed on the left feather, which ensures that there is no hint of fracture or abrasion on moving parts, as well as snagging on foreign objects.
Replacing the air filter on your KTM EXC 250 in seconds and without tools. But with foolproof protection!
The grips on the KTM EXC are replaceable and easy to remove and install, as is the lever protection. Changing the air filter, which had some issues last year, is now done in a matter of seconds. Moreover, it is simply impossible to install the filter incorrectly: it will not fall into place, and the lid will not slam shut.
KTM EXC 250 (2017)
Total
The entire 2021 KTM enduro range is new motorcycles designed from scratch and keeping in mind the latest trends in the market. EURO4 requires factories to reduce emissions and efficiency, and they, on the contrary, make ever more powerful and powerful engines - everything is on the path to radically increasing efficiency. Japanese companies, in particular Honda, took this path five years ago, but in terms of the off-road motorcycle market today they are significantly inferior to KTM in efficiency and concentration of technology. So if you are looking for a new 2021 enduro model, the KTM representative office in Russia is ready to sell it to you! Motorcycles are in stock at the company's warehouses. They are already being bought, especially from the regions.
The engines are lightweight, as is the chassis, which made it possible to reduce the total weight of the motorcycles from 2.1 to 5 kg per revision!!!
Detailed technical specifications can be found on the official KTM Russia website
MY MOTORCYCLE
For the 2021 model year, the KTM EXC lineup has seen perhaps its biggest changes since 2012. Motorcycles have become lighter, stronger and faster, and two-stroke models are completely revolutionary in their essence. The list of differences is so long, and they themselves are so comprehensive, that a few dry lines from a press release, as happened before, in this case cannot be done. One figure: only less than 10% of parts from predecessors were inherited by new models.
If you just sit with your eyes closed on one of the new EXC, the differences from previous models are barely noticeable. But on the move, these are completely different animals. All of them, both 2T and 4T, have certainly become lighter and more mobile. All-new frames and suspension components provide a smoother, more forgiving and versatile ride. Combined with their more powerful and wider range of engines, the 2021 EXC makes it much easier and more enjoyable to take off-road adventures. Even on such a slippery and rocky surface that awaited the participants of the premiere show in Spain.
KTM EXC 4T
In the 2021 model year, the names of four-stroke models are streamlined, now all of them have the letter F in their names, clearly indicating four-stroke. But this does not mean that the 450 and 500 cc models with SOHC gas distribution system received a twin-shaft DOHC configuration like the 250 and 350 cc engines. As we've already seen with the 2021 motocross lineup (and the 2017 EXC is based largely on that), the design of the new bikes is influenced by an obsession with weight savings and mass centralization. In addition to the fact that the new products managed to lose from 3 to 5 kg of weight, there was a radical shift in the center of gravity of the rotating masses (crankshaft and clutch), which had a noticeable impact on the handling characteristics. Combined with a new frame that is more longitudinally flexible and torsionally rigid, and an all-new WP Xplor fork and shock absorber, the 2021 KTM EXC's ride quality has moved to a whole new level.
250/350EXC-F: When the new 2021 KTM SX motocross models arrived a year ago with increased power, torque and low-end response, it became obvious that their engines would be a good basis for building enduro models. This is exactly what happened now. After a number of modifications specific and necessary for enduro, made in particular with the 350SX-F engine, in the EXC-F version it became even more torquey at the bottom and received shorter gears. This, for example, allows you to very smoothly navigate slow corners and narrow tracks in third gear with minimal clutch work. The 250, under the same conditions, requires slightly higher revs. The 350EXC-F can, as before, rush with the sound of a siren and at the same time has received such a width and versatility of the operating range that allows it to steer with the help of the rear wheel and make its way along the ruts at minimum speeds with rare shifts. The 250EXC-F delivers similar torque and responsiveness, which is always nice when it comes to a small engine size. There is no doubt that this bike has now become even better for less experienced riders or those who spend most of their time riding in difficult off-road conditions. The progress is not as impressive as in the case of its 350 cc brother, but in any case, coupled with a 3 kg lighter weight, improved chassis and suspension, you get a super responsive and obedient projectile that rides better than one might initially think.
450/500EXC-F: As with the 2016 450SX-F, losing an extra 5 kg makes the 2021 450EXC-F noticeably more agile. And this doesn’t even take into account the company’s overall commitment to compressing the center of gravity of its entire line of off-road motorcycles. Both “senior” 2021 models are distinguished by an expanded operating range of thrust and a more compliant nature of engine power delivery. Instead of simply installing a 450SX-F motor with a stretched ratio and increased flywheel weight, KTM has given these motors an entirely different set of rotating parts, from the crankshaft to the camshaft and everything in between. Including differences in the exhaust system, throttle body, fuel map, stator, gearbox, and so on. In other words, the EXC-F engines were designed and built specifically for off-road driving conditions, rather than being a simple conversion of the 450SX-F powerplant. From a handling standpoint, the new 450EXC-F is as nimble as the 350 while delivering more comfortable power delivery than the previous generation 450 and 500 EXC. Power at the crankshaft is 56 and 62 hp. (for 450 and 500 cm3 models respectively). The 500EXC-F has a higher gear ratio (13/50) and encourages you to cruise at slightly lower revs. Absolute control over engine thrust can be obtained by activating traction control, which smooths out all errors when handling the throttle and is especially helpful on slippery surfaces or, for example, if the pilot begins to get tired and the task is simply to get to the finish line or home.
KTM EXC 2T
If we try to express the feeling of the new EXC with dry numbers, then on the move the 4T models differ from their 2021 counterparts by 20 percent, and the 2T by all 50. Two-strokes would seem to look and sound the same as always, but with a balancer shaft for the first time Now available in their engines, they give a completely new feeling, free from vibrations and change your ideas about 2T. At all the premieres of past years, two-stroke enduros, due to their harsh and even angry nature, have never been as in demand among journalists as the 250EXC and 300EXC this year. It is thanks to the achieved amazing combination of power, controllability and low vibration levels. All this allows you to more fully concentrate on control and driving, without being distracted by the motorcycle, which constantly reminds you of its two-stroke nature. Adding to the tractability is a redesigned power valve mechanism, making the engine's performance super smooth and more tractable than before.
Back in 2012, when KTM first introduced the concept of using the frame as an additional shock-absorbing element, it was clear that two-strokes would benefit most from the marriage of frame and suspension. In 2021, when another significant step has been taken in this direction, 2T will continue to receive more tangible benefits from this. According to the developers, the higher vibration levels of previous generations of two-stroke enduros had a oscillating effect on the suspension springs and led to early wear of the suspension components and made it more difficult to fine-tune. The sharp reduction in vibrations in the 2017 models eliminated all these difficulties and the suspension itself became more responsive to certain settings.
WP XPlor suspension
Before the presentation, there were rumors that the new EXC would be equipped with the already well-known 4CS or AER forks, but KTM threw a surprise and installed a completely new WP XPlor fork and a new shock absorber on the 2021 enduro. There is no doubt that this will be a very positive change. Together with the more flexible characteristics of the new frame and swingarm, this suspension makes a significant contribution to outstanding handling. Both the front and rear handle small bumps very accurately and gently, but now they are able to take much stronger impacts without going all the way through. This makes the new EXC more versatile across a wide range of terrain and more comfortable for riders of varying weights and skill levels.
Another advantage of the new suspension is that it is noticeably lighter. The fork was lightened by 200 grams, and the rear shock absorber was able to lose about 600 grams. Fork tuning is similar to the previous 4CS model, with an easily accessible adjustment on the top of the seatstays. For even greater convenience, you can optionally install the ingeniously simple, tool-free fork pre-tension adjuster from the KTM Powerparts tuning catalog (comes standard on Six-Days models). With it you just need to hang the front wheel and then select the desired value of 0, 3 or 6 mm. It's a first-of-its-kind tool-less preload adjustment solution for front forks and WP know-how.
Traction control
As expected, the 2021 EXC comes with traction control, which was pioneered by the 2017 KTM and Husqvarna motocross models introduced earlier. It is obvious that enduro bikes will benefit more from this technology than motocross motorcycles. Instead of using a rear wheel sensor (which is prohibited by sport regulations), KTM's traction control system analyzes throttle signals and engine speed, and if the revs suddenly increase, reduces power to maximize wheel grip. This system operates much more precisely and smoothly than on large touring enduros, and only when absolutely necessary. On slippery surfaces, with this traction control it is much easier to keep the rear wheel in a straight line, and at the same time it remains responsive to the turn of the throttle. And under normal conditions, traction does not interfere with using the full potential of the engine, be it 250EXC-F or 500EXC-F. The only drawback of the system is the need for its optional activation, since traction control is not included in the standard equipment of 2017 motorcycles. You will also need to purchase an additional map switch/mode selector from the KTM Powerparts catalog. Six-Days models already have this switch installed straight from the factory. Traction works with both fuel maps, so you actually get four engine management modes. The map switch itself is much more convenient than that on previous models and makes it easy to operate on the go. The selected modes are displayed in different colors (white and green for maps 1 and 2, orange for traction control) and cannot be mixed up. The selected settings are saved the next time the engine is started.
source ktm-moto.ru
