Already renowned for its power, the new generation 250 SX-F features an even more powerful engine mounted on an entirely new chassis. By combining an engine offering more power and torque and a light and manoeuvrable chassis, the new 250 SX-F is sure to be the star of tomorrow.. The lightest and most capable motorcycle in its class, the 2016 250 SX-F is destined to maintain its champion position and is therefore the ideal choice for both amateur and professional riders..
The main objective of the KTM engineers during the development of the new generation SX was very significant weight reduction and improved handling. With a weight reduction of between 4 and 5 kg, the result is exceptional, making the new KTM models the lightest motorcycles on the market, and this although the four-stroke models are equipped as standard with a very beneficial electric starter, while competing models must be kicked off.
The new KTM SX models feature a revolutionary new ultra-light WP fork, a 48mm inverted air spring fork developed by WP Suspension in close collaboration with KTM. This is a split fork with separate functions for each fork leg. The damping functions are on the right, the air spring is on the left. The left fork leg houses an air cartridge. The air spring is easily adjusted to suit rider weight using a single valve and standard fork air pump. The right fork leg features a new cartridge specifically designed to meet the demands of the single damping arm design, and the damping can be adjusted to suit track conditions or rider preferences with a simple twist. button. With approximately 300mm of travel, the new fork offers exceptional response and excellent, consistent damping characteristics. It also achieves a weight saving of 1.4 kg compared to the previous model.
High quality CNC machined triple trees have been a trademark of KTM for years. Allowing precise steering, they significantly enhance the flexibility characteristics and, thus, the action of the fork. For 2016, the upper triple clamp has a new handlebar clamp rubber damping system to reduce the level of handlebar vibration. Forks maintain front-to-rear adjustability to rider preference.
The new generation of mono-shocks manufactured by WP Suspension have been designed for the new SX models, together with the new frame and swingarm architecture, modified linkage and new WP fork. The linkage system has also been reworked, with modified geometry and extended pull rods, and was tested last season on most KTM factory bikes..
The 250 SX-F engine is based on the general design of its predecessor, but received significant upgrades to achieve a more compact and lightweight MX2 engine. Torque and power have been improved throughout the speed range. One of the most spectacular advantages of the new design is a weight saving of 1.1 kg, for a total of 26.1 kg including the very beneficial electric starter. The new engine offers an improved power curve over the entire rev range up to 14,000 rpm, making the new 250 SX-F much easier to handle for both amateur and professional riders..
The centerpiece of the compact DOHC (Double Overhead Cam) engine is the new advanced cylinder head. It features improved combustion chamber geometry, two 150g lightened overhead camshafts with new distribution and an ultra-thin surface with optimized friction, new pawls with a 30% harder DLC coating and an improved timing drive (reduced friction and shorter DID timing chain, new guide bars and crowns). New valve springs and cups for the four ultra-light titanium valves (32.5mm intake, 26.5mm exhaust) and high-flow ports help maximize flow for optimum speed range and maximum performance up to ” at engine speed limit of 14,000 rpm.
Cylinder and piston
The improved, shortened cylinder with a bore of 78 mm accommodates a forged, reinforced and lightweight box-type piston manufactured by CP. The unique shape of the piston is adapted to the new combustion chamber and is characterized by a very rigid structure and low weight. Compression is 14.4: 1. The reduced oscillating masses give the engine an extremely responsive character.
The crankshaft of the new 250 SX-F offers greater rigidity and uses a shortened 6mm connecting rod, which contributes to the responsiveness of the engine. The big end bearing has two force-fitted half-bearings acting directly on the crankpin. This design is the prerequisite for achieving extremely high speeds and unrivaled engine power of 250 cm.³. It also improves engine longevity, allowing longer crankshaft overhaul intervals..
In order to balance mass forces, the new 250 SX-F engine uses a multifunctional balance shaft that drives the water pump and the timing chain at the same time. It is equipped with new crowns mounted on the new timing chain.
The new 250 SX-F is again fitted with an electric starter as standard, which is a decisive advantage in reducing lap times in competition. New Mitsuba electric starter (modified for ease of disassembly) and lightweight drive device improve starting efficiency and reliability.
Engine housings and cover
The completely new design of molded crankcases offers a much more centralized shaft configuration. With a number of further developments, it made it possible to shorten the engine by 20mm and achieve a much more centralized weight distribution. New magnesium engine covers feature an advanced surface structure to reduce wear caused by rider boots.
Engine management system
The completely redesigned Keihin electronic fuel injection engine management system features a new 44mm throttle body that delivers spontaneous response and maximum performance through a revolutionary injector position. The new ECU (Engine Control Unit) includes a cranking control function to improve starting efficiency and provides different configurations depending on the selection of the gear switch engaged. using the selector on the handlebars, the rider can also activate an optional configuration for a different power curve.
The new compact CSS (Coil Spring Steel) clutch features a lightweight, wear-free steel clutch housing, and 7 (instead of 8) clutch plates with very high heat resistance thanks to their discs steel brackets. The improved internal hub and pressure plate ensure better oil supply and better clutch cooling. The smaller diameter of the master cylinder of the Brembo hydraulic clutch system allows precise and easier modulation.
The new engine is fitted with an all-new, lightweight 5-speed gearbox. It offers the same ratios as the previous model, but is equipped with larger gears whose surface has received a special treatment for 2nd, 3rd and 4th gears, improving reliability. One of the new special features is the design "zero dirt" of the gear lever, which prevents dirt from blocking the lever joint, ensuring safe use of the gearbox.
The new airbox design provides optimum protection of the air filter against clogging and maximum air flow. The new intake snorkels feature a weight saving of 300g and are made of a new material (reducing deformation due to air intake impulses) improving performance. As on previous models, the new dual air filter allows easy and safe fitting, and can be changed in seconds without tools – an original KTM standard feature.
Battery and wire harness
As in the past, all SX-F engines are fitted with the proven electric starter – a KTM exclusive and a major advantage in motocross racing. For 2016, the SX-F range succeeded in integrating an ultralight and compact 495g lithium-ion starter battery on a standard motocross, allowing a safe start and a weight saving of 1 kg compared to 2015 !
High-tech Brembo brakes have always been a standard feature of KTM off-road motorcycles. They are combined with redesigned wave type discs, lightened and with improved thermal resistance manufactured by GALFER. The ultimate solution in braking technology. Weight reduction of 63 g at the front, 32 g at the rear.
The 250 SX-F features ultra-light CNC machined hubs, premium Excel rims, new lightweight spokes, and aluminum spoke heads that provide maximum stability at minimum weight. Dunlop’s new MX tires (Geomax MX 32) were developed with the KTM racing team in the USA based on factory tests and the racing experience of seasoned riders. They guarantee perfect traction and exceptional performance.
The new frame design offers approximately 20% greater torsional stiffness, approximately 30% lower longitudinal stiffness, and features redesigned engine mounts to reduce vibration. This gain in flexibility allows better absorption of the energy generated by the front and rear wheel loads, assisting the suspension for a gain in comfort and a reduction in pilot fatigue. The 0.4 ° greater steering angle and 10mm shorter wheelbase help improve handling, as well as 380g lighter weight compared to the previous model.
A new concept of footrests "zero dirt" Prevents dirt from jamming the footrests when they are brought back into position, even in deep ruts. The new footrests are also wider and more stable, offer better grip and are lighter than previous models..
As on previous models, the new generation SX is equipped with a new cast aluminum swingarm. The new one-piece molded swingarm offers reduced weight and optimized bending behavior enhancing damping characteristics. Weight gain is 250 g.
For the new generation of SX models, KTM factory riders collaborated on the body design with the R specialists&D KTM and Kiska Design. The aim was to achieve perfect harmony between the rider and the bike, down to the smallest detail. The result: new plastics offering perfect ergonomics and contact points for the rider, maximum freedom of movement, a saddle lowered by 10 to 20 mm (at the rear) and better comfort, especially at the rear saddle.
All models in the SX range are fitted with a new ultra-light polyethylene tank with a capacity of 7 liters. The tank cap with internal thread ensures easy and reliable closing. Four-stroke models are equipped with an integrated fuel pump system.
New modern IML graphics highlight the sporty character of the 2016 SX line-of-the-art motocross.
The new SX generation models are fitted with a new NEKEN tapered handlebars in high strength aluminum, mounted on a new clamp fitted with a damper gasket and offering two handlebar mounting positions.
All four-stroke models feature a new butterfly assembly with interchangeable cams for different opening characteristics, and new ODI handles with lockable mounting clamp on the left side. A selector allows you to select different configurations and activate a start control function.
Perfectly ergonomic, the new saddle offers a greater volume of foam plastic ensuring comfort and longevity for the same weight as the previous model.
The integrated KTM cooling system routes coolant from the cylinder head through the triangle of the frame to the new WP aluminum radiators, fitted with a new cap system and made of a more rigid alloy. Thanks to optimized internal circulation and ventilation calculated by CFD simulation, the cooling efficiency has been improved by approximately 10%. Sophisticated radiator guards provide effective protection in the event of an accident.
Info and media credits: KTM
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250 SX-F 2015
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The technical aspect
2016 KTM 250 SX-F
- Tank: 7 liters
- Wheelbase: 1,485 mm
- Dry weight: 98 kg
- Train before
- Secondary chain transmission
- Rear axle
(78 x 52.3 mm)