KTM has unveiled its 2016 motocrosss models in Italy overnight at the international press launch. Heavily based on the Factory Edition that took Ryan Dungey and Marvin Musquin to AMA Supercross titles this year, next season is shaping up to be a marquee year for the Austrian brand with the 2016 KTM SX-F and SX range.

While it’s anticipated that KTM Australia will import the US-spec model (which will feature the 4CS fork rather than the new air-sprung fork featured on European models), the base of the 2016 models have been detailed on KTM’s international website.

The European press introduction is taking place in Italy this week, while MotoOnline.com.au will join a select crew of Australian media at the US intro early next month. Following that, we will have detailed tests on every model in the range with former national champion Ryan Marmont as our exclusive test rider.

All MY 16 models

Airbox:
The new airbox design offers maximum protection of the air filter against soiling, while ensuring maximum airflow in conjunction with new and 300g lighter intake snorkels that are made of a new material (reducing the deformation due to air intake pulses) for improved performance. As found on previous models, the new Twin Air filter is easier and safer to mount and can be changed without tools in seconds, a standard, original feature by KTM.

Battery and wiring harness:
As in the past, all new SX-F engines are fitted with the proven electric starter – a unique KTM feature and a major benefit at all levels of motocross racing. For MY 2016 the SX-F range fits a super compact and lightweight 495g lithium-ion starter battery into a standard motocross bike, providing safe starting of the engine and reducing the weight by 1kg over MY 2015!

Brakes:
High-tech Brembo brakes have always been standard equipment on KTM off-road bikes and are combined with newly designed and weight-reduced Wave discs made by Galfer featuring also an improved heat resistance. The ultimate solution in braking technology. Weight reduction front 63g, rear 32g.

Seat:
Ergonomically perfect, the new seat has a higher foam volume, which offers great comfort and durability at the same time, while weighing the same as the previous model.

Frame:
The new frame design provides approximately 20 percent higher torsional rigidity and 30 percent less longitudinal stiffness, with newly designed engine stays for less vibration. This increased flexibility results in better absorption of the energy created from the front and rear wheel loads supporting the suspension for more comfort and less rider fatigue. A 0.4-degree steeper steering angle and a 10mm shorter wheel base contribute to better handling and last but not least it´s around 380g lighter than the previous model.

Footpeg:
A new sophisticated ‘no dirt’ footpeg solution prevents dirt from blocking the pegs and stopping them from returning to the proper position, even when digging in deep ruts. In addition the new footpegs are larger, more stable, lighter than on previous models and offer more grip.

Swingarm:
As on the predecessor models, the new SX generation features a reworked cast aluminium swingarm. The updated design offers reduced weight and an optimized flex behavior supporting the frame and suspension created with a single-component casting process. The weight reduction is 250 grams.

Bodywork:
For the new generation of SX models the KTM factory riders were involved in shaping the bodywork together with the specialists from KTM R&D and Kiska Design. The goal was to achieve complete harmony between rider and bike down to the finest details. The results are all-new plastics that provide perfect ergonomics and contact points for the rider, maximum freedom of movement, a lower seat height of between 10 to 20mm (rear-end) and better comfort, especially in the rear part of the seat.

Fuel tank:
All models of the SX range have new lightweight polythene tanks with a capacity of 7.0 liters of petrol. The filler cap with an inside thread makes for an easy and reliable closure. The four-stroke models are fitted with an integrated fuel pump system.

Graphics:
New modern in-mold graphics highlight the sporty character of the MY 2016 SX range of cutting-edge motocross bikes.

Cooling system:
The proven integrated KTM cooling system routes the coolant from the cylinder head through the frame triangle, directly to newly developed aluminium radiators made by WP, which have a new filler cap system and are made of a stiffer alloy. Due to flow optimised internal circulation and CFD-calculated air ventilation, the cooling efficiency has been improved by approximately 10 percent and the sophisticated radiator guards provide efficient protection in case of crashes.

Handlebar:
The new generation SX models are equipped with a new tapered handlebar made of high-strength aluminium by Neken, which is fixed in a new rubber damped handlebar clamp allowing the handlebar to be mounted in two different positions. All four-stroke models feature a new throttle assembly with exchangeable throttle cams for different opening characteristics and new ODI grips featuring lock-on fixing clamp on the left-hand side. In addition a map switch allows the selection of different maps and the activation of a launch control.

Monoshock:
The new generation of monoshock made by WP Suspension has been developed for the new SX models in conjunction with the new frame and swingarm architecture, including the reworked linkage system and the new WP forks. The linkage system has also been reworked with a revised geometry and longer pull rods, which was tested last season in most of the KTM factory bikes.

Forks:
Australia will use the US specification model, in which the SX-F models feature the advanced WP 4CS four-chamber closed cartridge fork with an updated setting for 2016. The 4CS fork has been specifically designed and adapted for motocross racing in the US. However, the European-spec KTM SX models are fitted with a revolutionary new and super-lightweight WP fork, a 48mm USD air-sprung fork developed by WP Suspension in close collaboration with KTM. It is a split fork with separate functions for each fork leg. The damping functions are on the right side, whereas the air spring is in the left. The left leg features a capsuled air cartridge. This air spring is easy to adjust to any rider weight via a single air valve and a standard fork air pump. The right fork leg integrates a completely new damping cartridge to fit single damping leg requirements, and the damping can be adjusted to the track conditions or the rider’s preferences with a twist of a dial.

Triple clamp:
Top quality, CNC-machined triple clamps have been something of a KTM trademark for years. Ensuring a precise handling, they perceptibly support the flex characteristics, and with it, the action of the forks. For MY 16 the upper triple clamp features a newly developed rubber damping system for the handlebar clamp in order to reduce the vibration level of the handlebar. The clamps retain their forward and back adjustability for any rider preference.

Weight reduction:
The main target for the KTM engineers when developing the new SX generation was a massive weight reduction in conjunction with an improved handling. The result of between 4 and 5kg is outstanding making the new KTM models the lightest bikes in the competition, even though the four-strokes are equipped with a super-beneficial electric starter as a standard feature, while the competitor models need to be kick-started.

Wheels:
The SX-Fs are fitted with lightweight, CNC-machined hubs, high-end Excel rims and new, weight reduced spokes with lightweight aluminium nipples providing maximum stability at minimum weight. The latest MX tires from Dunlop – the Geomax MX 32 – have been developed from KTM factory racing in the US, factory testing and expert rider feedback in racing. They guarantee perfect traction and outstanding performance.

Note: The 250 SX won’t feature all the upgrades of the new generation models alongside it in KTM’s 2016 range. See lower section of this article to view its differences in various areas.

2016 KTM 250 SX-F

Engine:
The new 250 SX-F engine is based on the similar overall design of its predecessor, with some major refinements to make this MX2 power plant more compact and lighter, with the production of improved torque and power across the entire rpm range. Perhaps one of the most impressive benefits of the new design is a weight reduction of 1.1kg to a total of 26.1kg, including the incredibly beneficial electric starter. The reworked power unit guarantees an improved power curve over the entire rev range up to 14,000 rpm, which makes the new 250 SX-F much easier to ride for both amateur and professional riders.

Cylinder head:
The centerpiece of the compact DOHC engine is the new cutting-edge cylinder head. It features improved combustion chamber geometry, two 150g lighter overhead camshafts with new timings, plus a friction-optimized super-fine surface, new finger followers with a 30 percent harder DLC coating and a reworked timing drive (friction reduced and shorter DID timing chain, new sprockets and chain guides). New valve springs and retainers for the four lightweight titanium valves (intake 32.5mm, exhaust 26.5mm) and high-flow ports create a maximised flow rate for an optimal power band and maximum performance, which concludes at an engine speed of 14,000 rpm.

Cylinder and piston:
In the reworked and shorter cylinder that has a bore of 78mm, is a weight-reduced, forged bridged box-type piston made by CP. It features a unique piston ground shape adapted to the new combustion chamber and stands out with its extra rigid structure, combined with a low weight. The compression ratio is at 14.4:1. Thanks to the low oscillating masses, the engine offers extremely lively characteristics.

Crankshaft:
The new 250 SX-F’s crankshaft features a stiffer design and employs a 6mm shorter connecting rod, contributing to the compact and light engine with a snappy power delivery. A plain big end bearing features two force-fitted bearing shells run directly on the crank pin. This design is a major prerequisite for the extremely high engine speed levels and the unrivalled maximum power of the 250cc engine. Not only that, it enhances the engine’s durability, allowing long crankshaft service intervals.

Counter balancer shaft:
In order to balance the mass-forces, the new 250 SX-F engine uses a multifunctional counter balance shaft, which at the same time drives the water pump and timing chain. It features new sprockets fitted to the new timing chain.

Electric starter:
The new 250 SX-F is again fitted with an electric starter as standard, which is well known as a clear advantage when it comes to crunch time in the heat of battle. A new starter motor made by Mitsuba (modified for easy disassembly) and a weight reduced starter drive guarantees more efficient and reliable starting.

Engine cases and cover:
The completely new design of the die-cast engine cases allowed for a much more centralized shaft configuration. This and further developments make the engine shorter by 20mm, while contributing to a much more centralised mass. Newly designed engine covers made of magnesium feature an advanced surface structure in order to reduce the wear caused by the rider’s boots.

Clutch:
The highly compact CSS clutch (Coil Spring Steel) features a weight reduced, wear-free steel basket, and now seven instead of eight clutch plates, which are extremely heat resistant due to their steel carrier discs. In addition, a reworked inner hub and a pressure plate guarantee a better oil supply along with even better cooling of the clutch. A smaller master cylinder diameter of the Brembo hydraulic clutch system provides easier and precise modulation.

Transmission:
The new engine is fitted with an all-new and weight reduced, five-speed gearbox. It features the same gear ratio as the previous model, but has wider gear sprockets, featuring a special surface treatment on the 2nd, 3rd and 4th gears for improved reliability. One of the new and special features on the bike is an advanced ‘no dirt’ gear lever design, which prevents dirt from blocking the joint of the lever and guarantees a safe activation of the transmission.

Engine management system:
The completely reworked Keihin Engine Management System, with electronic fuel injection, features an all-new 44 mm throttle body, which provides a spontaneous response and maximum performance thanks to a revolutionary injector position. The new ECU (Engine Control Unit) includes a launch control for more efficient starts with the provision of different maps according to the gear sensor selection. In addition, the rider can activate an optional map for a different power delivery via the map select switch on the handlebar.

2016 KTM 350 SX-F

Engine:
The new DOHC engine of the 350 SX-F features a completely new construction in order to make it even more compact and powerful than before. Fitted with the latest electronic fuel injection system and electric starter, it has a very wide usable speed range, high performance and incredibly efficient rideability. The new design made the engine 20mm shorter than previously, while reducing the weight by 1kg to only 27.2kg.

Cylinder head:
The new cylinder head features an improved combustion chamber geometry, two overhead camshafts with a friction-optimised super-fine surface, new finger followers with a 30 percent harder DLC coating and high-flow ports. In conjunction with new valve springs and retainers for the four lightweight titanium valves (intake 36.3mm, exhaust 29.1mm) the flow rate has been maximized for an optimal power band, with more performance across the entire range, which ends at an engine speed of 13,400 rpm. The peak performance now is at 58hp.

Cylinder and piston:
In the redesigned and shorter cylinder, with a bore of 88mm, works a weight reduced forged bridged box-type piston made by CP. Its new piston crown geometry is adapted to the new high-compression combustion chamber and stands out with its extra rigid structure, combined with a low weight. The compression ratio is at 14:1. Thanks to the low oscillating masses, the engine offers extremely lively characteristics.

Crankshaft:
The new 350 SX-F’s crankshaft is lighter and features a stiffer design than previously. It utilises a shorter connecting rod, contributing to the compact and light engine with a typically snappy power delivery. This design is a major prerequisite for the extremely high engine speed levels and the unrivalled maximum power of the 350cc engine. Not only that, it enhances the engine’s durability, allowing long crankshaft service intervals.

Electric starter:
The new 350 SX-F is fitted with an electric starter as standard, which is well known as a clear advantage when it comes to crunch time in the heat of battle. A new starter motor made by Mitsuba (modified for easy disassembly) and a weight reduced starter drive guarantees more efficient and reliable starting.

Clutch:
The highly compact CSS clutch (Coil Spring Steel) features a weight reduced, wear-free steel basket, and now seven instead of eight clutch plates, which are extremely heat resistant due to their steel carrier discs. In addition, a reworked inner hub and a pressure plate guarantees a better oil supply along with even better cooling of the clutch. A smaller master cylinder diameter of the Brembo hydraulic clutch system provides easier and precise modulation.

Transmission:
The new engine is fitted with an all-new and weight reduced, five-speed gearbox. It features the same gear ratio as the previous model, but has wider gear sprockets, featuring a special surface treatment on the 2nd, 3rd and 4th gears for improved reliability. One of the new and special features on the bike is an advanced ‘no dirt’ gear lever design, which prevents dirt from blocking the joint of the lever and guarantees a safe activation of the transmission.

Engine cases and covers:
The completely new design of the die-cast engine cases allowed for a much more centralised shaft configuration, raising the crankshaft by 6mm closer to the bike’s center of gravity. Newly designed engine covers made of magnesium feature an advanced surface structure, which reduce the wear caused by the rider’s boots.

Engine management system:
The completely reworked Keihin Engine Management System, with electronic fuel injection, features an all-new 44mm throttle body, which provides a spontaneous response and maximum performance thanks to a revolutionary injector position. The new ECU includes a launch control for more efficient starts with the provision of different maps according to the gear sensor selection. In addition, the rider can activate an optional map for a different power delivery via the map select switch on the handlebar.

Counter balance shaft:
In order to balance the mass-forces, the new 350 SX-F engine also uses a multifunctional counter balance shaft, which at the same time drives the water pump and timing chain. It features newly designed sprockets fitted to the new timing chain.

2016 KTM 450 SX-F

Engine:
With new features such as its much more compact dimensions, stronger performance throughout the rev range and a weight reduction of 1.8kg, this newly-developed powerplant is the lightest 450 engine on the MX market. With a reworked single overhead camshaft cylinder head and the latest electronic fuel injection, it is distinguished by unrivalled power of more than 62hp and a highly efficient power delivery.

Cylinder head:
Inside the newly designed cylinder head with its reworked water jacket and combustion chamber, the gas flow through the optimized ports is controlled by an all-new overhead camshaft. This activates four ultra-lightweight titanium valves via extremely rigid rocker arms, which are DLC coated on the intake side. This configuration allows engine speeds of up to 11,500 rpm. In addition, the head is 350g lighter than the previous model due to the compact design.

Cylinder head and piston:
In the reworked and 6mm shorter cylinder, featuring an optimized water jacket and a bore of 95mm, is an extremely lightweight box-in-box type piston together with a weight optimised piston pin that delivers a major contribution to the engine’s low vibrations and engine-speed strength. The compression ratio is 12.6:1.

Crankshaft:
The 450 SX-F’s crankshaft features 10 percent more inertia (without increasing weight) and utilises a shorter connecting rod over the previous model, which contributes to an overall compact and light engine with a snappy power delivery. A higher balancing factor reduces the vibration level. A plain big end bearing with two force-fitted bearing shells runs directly on the crank pin, and the oil feed for this is ensured by the engine’s pressure lubrication. An overall design that offers the customer lengthened service intervals.

Counter balance shaft:
The weight optimised, side-mounted counter balance shaft at the same time drives the water pump. Thanks to the perfect mass balancing and this powerhouse’s low total oscillating masses, engine vibrations can be kept to a minimum even at the highest engine speeds.

Electric starter:
Like all KTM four-stroke motorcycles, the 450 SX-F is started with ease by pushing a button. Especially in the heat of a motocross battle, as demonstrated time and time again, an electric starter can become an invaluable advantage.

Engine cases and covers:
The completely new design of the die-cast engine cases allows for a much more centralized shaft configuration, raising the crankshaft by 7mm and 9mm backwards closer to the bikes center of gravity – a weight saving of 550g and a weight reduction to 27.3kg (EU), 27.8kg (US). Newly designed engine covers made of magnesium feature an advanced surface structure in order to reduce the wear caused by the rider’s boots.

Clutch:
The 450 SX-F employs the KTM-developed DDS clutch (Damped Diaphragm Steel) with a wear-free steel basket and extremely heat resistant clutch plates. This design is distinguished by employing a diaphragm spring instead of the usual coil springs, which makes for a considerably easier clutch action. The diaphragm spring also leaves sufficient space for a damping system integrated into the clutch hub, which benefits for both traction and durability.

Transmission:
The new engine of the 450 SX-F uses a lightweight 4-speed gearbox with unchanged gear ratios that are perfectly matched to the power delivery of the large displacement engine. In addition the 1st and 3rd gears are now treated with a special surface treatment for better reliability. On the US market, the 450 SX-F is delivered with a 5-speed gearbox in order to meet the demands of the American (and Australian) customers using the bikes on faster tracks and for desert rides.

Engine management system:
The completely reworked Keihin Engine Management System, with electronic fuel injection, features an all-new 44mm throttle body, which provides a spontaneous response and maximum performance thanks to a revolutionary injector position.

2016 KTM 125 SX

Engine:
The newly developed 125cc engine for MY 2016 features a completely new architecture with the latest KTM engineering know-how and the most advanced technology in the class. The result is that it produces better power all over the rev range, it is with 17.2kg more than 2kg lighter than the predecessor and it is much more compact. The benefit for the rider will be reflected in faster lap times due to better rideability and higher performance.

Cylinder:
Within the heart of the new engine is a newly designed cylinder that has a bore of 54mm. Apart from reworked ports, it features a newly developed power valve unit with a sophisticated mechanism for the lateral support exhaust ports. Together with a new two-component cylinder head, this is the key for a massive performance increase over the entire range. Even though it is 360g lighter and more compact than the previous model, the new layout of the water jackets in the cylinder and head guarantee a better heat dissipation, which is important when the going gets tough.

Die-cast engine cases:
For the latest engine generation the KTM engineers designed all new die-cast engine cases featuring a 27mm higher clutch shaft and 37mm higher crankshaft position, which has resulted in better mass centralisation for improved rideability. In addition, the engine body is much more compact and this contributes massively to the weight reduction (600g lighter).

Piston:
The new 125 SX piston is optimised for maximal reliability and the reworked shape fits perfectly to the new cylinder layout.

Transmission:
A new 6-speed transmission provides the same gear ratios as the previous model, but due to the latest production technologies the width could be reduced by 6mm and the weight reduced by 200 g. An advanced ‘no dirt’ gear lever design prevents dirt from blocking the joint of the lever guaranteeing safe activation of the transmission.

Exhaust:
For the new model our engineers developed a new, specifically tuned exhaust pipe in order to get the maximum power output of the engine.

New crank shaft:
The new crankshaft provides the same stroke of 54.5mm as in the past, but it features an optimised balancing for minimum vibration while being 50g lighter.

Clutch:
The new engine features a new hydraulic clutch mechanism made by Brembo instead of Magura. It ensures an easy clutch action and well-defined modulation.

2016 KTM 150 SX

Engine:
The engine of the 150 SX has been known to be the most powerful and most competitive engine of the class. But it was time to give a new push to the segment and set a clear statement, that the two-stroke technology is going to have a successful future due to its outstanding power-to-weight ratio, low cost and simplicity. The newly developed 150cc engine for MY 16 features a completely new architecture with the latest know-how and state-of-the-art technology. The result is that it produces better power all over the rev range, it is more than 2kg lighter than the predecessor and it is much more compact.

Cylinder:
The heart of the new engine is the newly designed cylinder with a bore of 58 mm. Apart from reworked ports it features a newly developed power valve unit with a sophisticated mechanism for the lateral support exhaust ports. Together with a new two-component cylinder head it is the key for a massive performance increase over the entire range. Even though it is 360 g lighter and more compact than the predecessor the new layout of the water jackets in the cylinder and head guarantee a better heat dissipation, which is important when the going gets tough. The cylinder, head and piston unit can now also be fitted on a 150 cm³ engine base converting it to a 150 SX without replacing the crankshaft.

Die-cast engine cases:
For the latest engine generation the KTM engineers designed all new die-cast engine cases featuring a 27mm higher clutch shaft and 37mm higher crankshaft position, which has resulted in better mass centralisation for improved rideability. In addition, the engine body is much more compact and this contributes massively to the weight reduction (600g lighter). Above that it is designed for an optional implementation of an electric starter.

Piston:
The new 150 SX piston with a diameter of 58 mm is designed for maximal reliability and the reworked shape fits perfectly to the new cylinder layout.

Transmission:
A new 6-speed transmission provides the same gear ratios as the previous model, but due to the latest production technologies the width could be reduced by 6 mm and the weight reduced by 200 g. An advanced ‘no dirt’ gear lever design prevents dirt from blocking the joint of the lever guaranteeing safe activation of the transmission.

Exhaust:
For the new model our engineers developed a new, specifically tuned exhaust pipe in order to get the maximum power output of the engine.

New crankshaft:
For the new model the crankshaft provides the same stroke of 54.5mm as the 150cc engine and it features an optimized balancing for minimum vibrations and it is 50g lighter.

Clutch:
The new engine features a new hydraulic clutch mechanism made by Brembo instead of Magura. It ensures an easy clutch action and well-defined modulation.

2016 KTM 250 SX

Engine:
The powerful KTM 250 SX engine unites an unbeatable power-to-weight ratio with outstanding performance and extremely easy handling.

Cylinder:
The cylinder of the 250 SX is fitted with a sophisticated TVC (Twin Valve Control) power valve, providing adjustable power characteristics, which can be changed within a few seconds thanks to two supplied springs offering optimal settings for different tracks and rider preference.

Clutch:
The KTM DDS (Damped Diaphragm Steel) clutch is fitted with a diaphragm spring, which allows implementation of an internal rubber damping system. Together with a lightweight steel basket and the Brembo hydraulic system the DDS clutch stands for maximal reliability, excellent modulation and low lever force.

Carburetor:
The 250 SX is fitted with a proven Keihin PWK 38S AG carburetor producing the perfect air-fuel mixture over the entire range at average conditions. For extreme temperature or altitude the setting can be tuned with supplied jets and needles according to a setting list in the manual.

Frame:
The modern frame design of the 250 SX, comprising lightweight, high strength, chrome-molybdenum steel section tubes, combines maximum longitudinal stiffness with optimum torsional stiffness.

Linkage/shock absorber:
The linkage system of the 250 SX features a progression curve with a high initial rate ensuring good stability. The high-end WP 5018 shock absorber guarantees outstanding response and damping characteristics and of course compression and rebound damping can be adjusted to the track conditions and the rider’s preferences.

Fork:
The fully adjustable upside-down closed cartridge fork from WP Suspension features a diameter of 48mm and provides excellent damping characteristics. It is adjustable in rebound and compression.

Graphics:
A new, refined graphic design with clear lines underlines the high demands made of a modern, state-of-the-art off-road motorcycle.

Bodywork:
KTM engineers have focused on designing the bodywork ergonomically and functionally in such a way that the whole motorcycle is in perfect harmony with the rider down to the very last detail. The front fender is a perfect example of how molded plastic components can gain maximum stability with a well thought out structure and well-conceived attachment.

Seat:
The ergonomically perfectly designed seat is equipped with a durable foam core, ensuring both greater comfort and higher stability.

Airbox:
At the same time, the design of the airbox guarantees optimum protection of the air filter from dirt plus maximum air throughput for the highest performance. Quick replacement of the Twin Air filter – without tools and in a matter of seconds – has long since been an unrivalled KTM standard.

Complete details on the new-look range including the 85 SX, 65 SX and 50 SX models can be found by visiting www.ktm.com. KTM Australia is expected to release further information on the models locally shortly.

Update: To read our first impressions on the entire range following the US media launch at the hands of former national MX2 champion Ryan Marmont, click this exclusive link on MotoOnline.com.au.