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Bodywork & Graphics

• BODYWORK & GRAPHICS: With input from KTM's factory riders, as well as KTM R&D and Kiska Design, the new bodywork of the KTM 300 EXC TPI pushes the boundaries of progression even further. The result is a shape across the entire range, that achieves complete harmony between rider and bike. The main goal was to provide the optimal contact points that allow a rider maximum freedom of movement and improved handling. The front and rear fenders feature an intelligent I-beam design, guaranteeing maximum stability with the lowest possible weight. A new tail light design fits perfectly to the new shape of the rear fender and the number plate carrier. The new in-mold graphics confirm the high-performance intentions of this bike, as well as KTM's never-ending quest for race-winning progression.
• FOOTPEGS: Sophisticated ´No-Dirt´ footpegs prevent clogging 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.

Chassis

• CHASSIS: When it comes to 2-stroke weaponry, keeping weight down is key. It should come as no surprise then that the KTM 300 EXC TPI is one of the lightest, slimmest and most agile enduro machines in its class.
• FRAME: 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.
• SWINGARM: The KTM 300 EXC TPI's one-piece aluminum swingarm is manufactured using a gravity die-cast production process, offering exceptional strength at the lowest possible weight. The single-component casting process offers low weight, perfect flex behavior and also allows for a large number of geometry solutions.
• WHEELS: Every extreme enduro rider is looking for reliable forward momentum and the KTM 300 EXC TPI ERZBERGRODEO edition guarentees this with the highest quality CNC machined factory wheels with anodized orange hubs. To ensure your progress is never haulted, even in the toughest, most slippery conditions, it comes standard with the soft version of the METZELER EXTREME rear tire.
• FRONT SUSPENSION: 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. So the fork can easily be adjusted for compression and rebound with the twist of a dial on top of the fork tubes (30 clicks each). In addition, a longer and sealed hydro-stop guarantees better resistance to bottoming-out. Due to high-quality materials and a state-of-the-art production process, the WP Xplor 48 fork – with approx. 300mm of travel – has outstanding response and damping characteristics. For 2018 redesigned outer fork tubes provide better flex characteristics for reduced stiction and less friction with a new setting for a more compliant feel. An optional preload adjuster allows for a threefold spring preload setting without any tools. Easy as one, two, three.
• REAR SUSPENSION: The WP XPLOR shock absorber is the key element on the proven PDS rear suspension design (progressive damping system), where the shock is directly linked to the swingarm without an additional linkage system. This keeps weight lower and reduces the chances of hooking on rocks. Optimal enduro-specific damping progression is achieved by using a second damping piston in combination with a closed cup towards the end of the stroke, and supported by a progressive shock spring. For 2020, improvements to the second piston, as well as a reworked shape and sealing of the cup, lead to improved resistance against bottoming without any sacrifice of comfort. New settings on the XPLOR PDS shock provide better damping characteristics and match the new frame and reworked front-end set-up perfectly. It is fully adjustable, including high and low-speed compression, so you can set the shock up to suit any track, trail and rider preferences.
• TRIPLE CLAMP: The 300 XC-W TPI is 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; this XC-W will fit you like your favorite gloves.
• BRAKES: These high-tech Brembo babies are combined with lightweight wave brake discs, including a solid disk on the rear. You couldn't brake any harder or with better feel on an offroad motorcycle. The ERZBERGRODEO edition provides extra reliability with a front and rear brake disc guard, as well as a rear brake safety wire.
• FUEL TANK: All models in the EXC range are fitted with newly designed lightweight polyethylene tanks improving the ergonomics. The ¼‐turn bayonet filler cap makes for quick and easy closure. Manufactured using see‐through plastic, you will always be able to see how much fuel remains at a glance. It is fitted with an integrated fuel pump system and a fuel level sensor. Additionally, the fuel line features a 90° connector to the tank for better protection against damage.
• AIRBOX: The new airbox on the KTM 300 EXC TPI ERZBERGRODEO 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.

Engine & Exhaust

• ENGINE: The 300 cc 2-stroke engine is known and respected for offering the most powerful 2-stroke performance in its segment. Thanks to state-of-the-art engineering, innovative 2-stroke design and revolutionary TPI fuel injection technology, the 2020 powerplant is more refined than ever before. The compact and lightweight 2-stroke is a great choice for all Enduro riders searching for easy-to-ride Enduro performance with the power and torque to conquer the most extreme climbs. With Euro IV homologation, it's not only considerately green, but leaves the competition green with envy too.
• CYLINDER: The cylinder on the KTM 300 EXC TPI ERZBERGRODEO edition, has a bore of 72mm and is fitted with a sophisticated power valve, which provides really smooth and controllable power characteristics. For the EFI application the cylinder features two lateral domes which hold the fuel injectors that supply fuel to the rear transfer ports. The downstream injection guarantees excellent atomization of the fuel with the upstreaming air. Thus, the loss of unburnt fuel is minimal 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. As of the 2020 model, the cylinders feature an improved power valve unit with a sophisticated mechanism for the lateral support exhaust ports. The new exhaust port layout increases engine performance, while the upper contour of the exhaust port has been machined to ensure more accurate port timing. Last but not least the new models allow the use of a more widely available type of traditional spark plug.
• CRANKCASES AND ENGINE COVERS: The compact engine cases are manufactured using a high pressure die-cast production process which helps with weight reduction, while retaining strength and durability. The design allows for optimal shaft arrangements close to the center of gravity, resulting in ideal mass centralization and easier ride-ability. This model comes with a special PowerParts oil pug and together with the smart surface structure on the engine covers, it will continue to look as fresh as the day you bought it.
• TRANSMISSION: This 6-speed transmission features an Enduro-specific wide-ratio specification and provides precise and easy shifting. 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.
• ENGINE MANAGEMENT SYSTEM: The engine management system (EMS) of the TPI models features a control unit located below the seat. The ECU defines the ignition timing and amount of fuel to inject is based on several sensor readings such as intake air pressure, throttle position and water temperature plus a new additional ambient air pressure sensor. Thanks to altitude and temperature compensation the rider does not need to worry about fiddling around with the jetting anymore. Should the rider decide to mount a radiator fan from the KTM PowerParts program, it will be controlled directly by the EMS without needing to add an additional thermal switch. The Erzberg edition comes with a map select switch, which allows the rider to select between a standard and advanced map while on the fly, for the optimal power delivery in every condition.
• BALANCER SHAFT: 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, more racing.
• CLUTCH: The KTM 300 EXC TPI ERZBERGRODEO employs the KTM-developed DDS clutch (damped diaphragm steel) with a wear-free steel basket, extremely heat resistant clutch plates and 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 without compromising durability. Light operation and a 'telepathic' level of control come standard with this hydraulic Brembo actuated clutch. Additionally, this model comes with clutch slave cylinder protection.
• OIL PUMP: Pre-mixing 2-stroke fuel is a thing of the past for KTM EXC TPI owners. The 2020 models are fitted with a newly designed 2-stroke oil tank featuring reworked and more flexible mountings, which greatly improve durability and reliability. In addition, a mesh filter helps prevent dirt getting into the oil pump. Mounted below the oil tank, the oil pump delivers the lubricant directly to the throttle body, where it is mixed with the incoming air to lubricate the piston and crankshaft. Using engine speed and throttle position sensor data, the engine management's precise electronic control of the oil pump ensures that the ideal amount of oil for any given conditions is used. The filler cap assembly for the oil tank is located between the fuel tank and steering head, utilizing a hose in the upper frame tube to transfer the oil to the storage container. With an average fuel-to-oil ratio of 1:80, the oil capacity of about 0.7 liters is sufficient for at least five tanks of fuel.
• THROTTLE BODY: The TPI engine is fitted with a redesigned 39mm throttle body made by Dell`Orto. The airflow is regulated by a butterfly connected with a twin-cable throttle cam, which is operated by the handlebar throttle assembly. A throttle position sensor provides airflow data to the control unit. For MY20 the idle system was reworked allowing the idle speed to be set more precisely via the bypass screw. Also, the cold start system is improved for a better supply of extra air when opening a bypass. Oil supplied by the electronically controlled oil pump via an oil intake tube is mixed with the incoming air to lubricate the moving engine parts.
• TPI ALTERNATOR: To accommodate the power requirements of the upgraded engine management system, the TPI models are fitted with a powerful 196 W alternator and a voltage regulator. The same as can be found on the EXC-F 4-stroke models.
• COOLING: The KTM 300 EXC TPI ERZBERGRODEO features newly designed radiators, which are mounted 12 mm lower than previous 300 EXC models. This lowers the center of gravity and matches the design of the new shrouds perfectly, in order to achieve perfect ergonomics. Above that a reworked delta distributor, integrated into the frame triangle, features a 4 mm larger center tube making the coolant flow from the cylinder head to the radiators more efficient. This special model comes with a radiator fan and an expansion canister. Thus, in case of overheating any coolant blowing over will be collected and given back into the radiator when the system cools down again. The radiators also benefit from special protectors that serve as protection from flying rocks and debris, as well as a brace that disperses energy around the radiators in the event of an impact.
• EXHAUST: 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.

Ergonomics & Comfort

• ERGONOMICS & COMFORT: Designed for complete harmony between rider and bike, KTM has exploited the knowledge from decades of race success to create perfect ergonomics on the KTM 300 EXC TPI. Maximum rider comfort and movement in all conditions is guaranteed. Additionally, the bike features a new tail light design which fits perfectly to the new shape of the rear fender and the number plate carrier.
• HANDLEBAR: 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.

Software & Electronics

• SOFTWARE & ELECTRONICS: KTM EXC TPI models feature the most modern engine management system of any 2-stroke off-road motorcycle. By reading various sensor data inputs, such as intake and ambient air pressure, throttle valve position and water temperature, the control unit optimizes ignition timing and the amount of fuel to inject at all altitudes and conditions.
• BATTERY & WIRING HARNESS: All engines are fitted with the proven electric starter, which is a major benefit for any offroad activity. It is powered by a super lightweight 2 ah lithium-ion starter battery which provides safe, reliable starting. A reworked wiring harness and revised packaging has most of the electrical components concentrated into a common area below the seat, making them more accessible and reliable.