2016 KTM 450 SX-F

Changes to 2016 KTM 450 SX-F

2016 KTM 450 SX-F

Massive Weight Reduction on the 2016 KTM 450 SX-F

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!

2016 KTM 450 SX-F

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.

NEWLY DESIGNED CHASSIS

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” foot peg 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

foot pegs are larger and more stable, provide better grip and they are also lighter than on

previous models.

2016 KTM 450 SX-F

SWINGARM

As on the predecessor models, the new SX generation features a reworked cast aluminium swing arm. The updated design offers reduced weight and an optimized flex behaviour

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 litres

of petrol. The filler caps with an inside thread makes for an easy and reliable closure. The 4-

stroke models are fitted with an integrated fuel pump system.

2016 KTM 450 SX-F

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 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.

2016 KTM 450 SX-F

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 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.

STATE-OF-THE-ART SUSPENSION

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 swing arm 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.

2016 KTM 450 SX-F

FORKS

The KTM 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 USA.

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 kick started.

2016 KTM 450 SX-F

THE 450 POWERHOUSE

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 power

plant 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.

2016 KTM 450 SX-F

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.

2016 KTM 450 SX-F

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 centre 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.

2016 KTM 450 SX-F

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.

2016 KTM 450 SX-F

UNRIVALLED HANDLING

WHEELS

The 450 SX-F is 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 (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 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 63 g, rear 32 g.