2016 KTM 450 SX-F

Frame

The new frame design provides approximately 20 % higher torsional rigidity and 30 % 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° steeper steering angle and a 10 mm shorter wheel base contribute to better handling and last but not least it´s around 380 g lighter than the previous model.

Footpeg

A new sophisticated “No-Dirt” footpeg solution prevents dirt from blocking the pegs in order to bring them back into position, even when digging in deep ruts. In addition the new footpegs are larger and more stable, provide better grip and they are also lighter than on previous models.

Swingarm

As on the predecessor models, the new SX generation features a reworked cast aluminum 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 20 mm (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 4-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 aluminum radiators made by WP, which have a new filler cap system and are made of a stiffer alloy. Due to flow optimized internal circulation and CFD-calculated air ventilation, the cooling efficiency has been improved by approximately 10 % 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 aluminum by NEKEN, which is fixed in a new rubber damped handlebar clamp allowing the handlebar to be mounted in two different positions.All 4-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.

Airbox

The new airbox design offers maximum protection of the air filter against soiling, while ensuring maximum airflow in conjunction with new and 300 g 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 495 g lithium-ion starter battery into a standard motocross bike, providing safe starting of the engine and reducing the weight by 1 kg over MY 2015!

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.

Wheels

The 450 SX-F is fitted with lightweight, CNC-machined hubs, high-end Excel rims and new, weight reduced spokes with lightweight aluminum nipples providing maximum stability at minimum weight. The latest MX tires from Dunlop (Geomax MX 32) have been developed from KTM factory racing in the USA, factory testing and expert rider feedback in racing. They guarantee perfect traction and outstanding performance.

Brakes

High-tech Brembo brakes have always been standard equipment on KTM offroad 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 63 g, rear 32 g.

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

The KTM SX models are fitted with a revolutionary new and super-lightweight WP fork, a 48 mm 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. The new fork with approximately 300 mm travel has outstanding response and excellent, very consistent damping characteristics, while also with a reduced weight of 1.4 kg compared to its predecessor.

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 5 kg is outstanding making the new KTM models the lightest bikes in the competition, even though the 4-strokes are equipped with a super-beneficial electric starter as a standard feature, while the competitor models need to be kickstarted.

Engine

With new features such as its much more compact dimensions, stronger performance throughout the rev range and a weight reduction of 1.8 kg, 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 62 hp 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 350 g lighter than the previous model due to the compact design.

Cylinder head and piston

In the reworked and 6 mm shorter cylinder, featuring an optimized water jacket and a bore of 95 mm, is an extremely lightweight box-in-box type piston together with a weight optimized 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 % more inertia (without increasing weight) and utilizes 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 optimized, 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 4-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 7 mm and 9 mm backwards closer to the bikes center of gravity – a weight saving of 550 g and a weight reduction to 27.3 kg (EU), 27.8 kg (USA). 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 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 44 mm throttle body, which provides a spontaneous response and maximum performance thanks to a revolutionary injector position.