The new generation KTM 250 EXC TPI is the ultimate combination of power and rideability. It has been completely reworked for 2020 and sets a clear benchmark for intuitive handling, unique style and top performance. Thanks to its groundbreaking TPI (transfer port injection) technology, this extreme machine continues to reach new heights, clearly demonstrating KTM's unrelenting commitment to 2-stroke development. Besides the renowned benefits of excellent fuel efficiency, clean exhaust emissions and the removed need for jetting, the new KTM 250 EXC TPI features a new dynamic, lightweight frame. It was developed with feedback from factory riders and in hindsight, returns the favor by offering excellent rider feedback.
The 250cc 2-stroke engine has plenty power and torque, but remains light enough for riders to muscle their way through the toughest obstacles. Thanks to state-of-the-art engineering, innovative 2-stroke design and revolutionary TPI fuel injection technology, the 2020 powerplant is even more refined than ever before. The compact and lightweight 2-stroke is a great choice for offroad riders who want usable enduro performance that is ready to conquer in the most extreme terrain. With Euro IV homologation, it's not only considerately green, but leaves the competition green with envy too.
Maintaining the optimal engine temperature is crucial to ensuring consistent horsepower throughout the ride. The KTM 250 EXC TPI features newly designed radiators which are mounted 12 mm lower than the predecessors. This lowers the center of gravity and matches the design of the new shrouds perfectly, in order to achieve perfect ergonomics. By using CFD technology (computational fluid dynamics) together with a clever coolant circuit routing, the innovative system ensures the optimum engine temperature for the highest performance, no matter what the conditions. Above all, a reworked delta distributor, integrated into the frame triangle, features a 4 mm larger center tube, increasing the cross section by 57%, making the coolant flow from the cylinder head to the radiators more efficient. The radiators also feature special protectors that don't only serve as protection from flying rocks and debris but also as a brace that disperses energy around the radiators in the event of an impact.
When it comes to improved power delivery and performance, the new exhaust plays a key role and packs a punch that is hard to beat. The 250 cc and 300 cc models feature new HD exhaust pipes (heavy-duty) made by using an innovative 3D stamping process which produces a ripped surface finish. This makes the pipe much stronger, with better resistance against rocks, while also helping to reduce noise drastically. The silencer features a new shape and end cap with reworked internal designs individually developed for each model. The plastic silencer holder is now replaced with lightweight, welded mounting brackets. In addition, the exhaust's new shape provides slimmer ergonomics and more ground clearance, while a new perforated inner silencer tube works with lighter damping wool for more efficient and more durable noise reduction. This adds up to a weight reduction of approximately 200 grams.
All EXC models feature new high-tech, lightweight chromoly steel frames. This includes hydro-formed elements produced by state-of-the-art robot welding. They retain their race-proven geometries, but by re-designing certain areas, the stiffness has been optimized, resulting in better feedback for the rider, playful handling and improved stability. The laterally attached engine head stays (the connection between cylinder, head and frame) are now made of aluminum, reducing vibration and further contributing to precise cornering. The bikes also feature newly designed lateral frame guards with a structured surface, improving grip, while also serving as a heat protector against the muffler on the right side. On the KTM 250 EXC frame, the engine is lowered by 1° around the swing arm pivot improving front wheel traction significantly. The subframe is made of extra-light and stable aluminum profiles, weighing less than 900g and is 40 mm longer than before, providing better rear fender stability.
All EXC models are fitted with the latest 48 mm diameter WP XPLOR upside-down forks, featuring a split fork design developed by WP and KTM. While each side is fitted with springs, they have separate damping functions. Compression damping is on the left and the rebound on the right. Both can easily be adjusted via the dials on top of both fork tubes with 30 clicks each. Although already distinguished for outstanding response and damping characteristics, the 2020 fork features a calibrated mid-valve piston for more constant damping. It also has new upper fork caps and clicker adjusters for easier adjustment with a new color and graphic design. The new settings keep the front end higher, providing increased reserves against bottoming out.
The new airbox on the KTM 250 EXC TPI has been completely reworked to ensure better flow dynamics, and together with new intake snorkels, results in optimal power and throttle response. Despite the obvious performance enhancements, the new design also offers maximum protection against soiling of the air filter. The large twin-air air filter is mounted on a cleverly designed stiff cage that minimizes incorrect installation. As found on previous models, filter maintenance is quick and easy and does not require tools - a standard, original feature from KTM.
All KTM EXC models are equipped with the same high-strength aluminum tapered handlebar, made by NEKEN. The handlebar allows for four different positions. The handlebars come standard with an ODI vulcanized grip on the right side and a comfortable ODI lock-on grip, which does not require any wire or glue, on the left. Additionally, all models can be equipped with an optional handlebar map select switch, which allows to select between a standard and advanced power curve.