RACE TO NEW HEIGHTS

KTM 250 XC-W TPI

KTM 250 XC-W TPI 2021

Base Price: 135,999.00 ZAR*

The new generation KTM 250 XC-W TPI is the ultimate combination of power and rideability 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 KTM 250 XC-W TPI features a dynamic, lightweight frame. It was developed with feedback from factory riders and in hindsight, returns the favor by offering excellent rider feedback.
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The new generation KTM 250 XC-W TPI is the ultimate combination of power and rideability 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 KTM 250 XC-W TPI features a dynamic, lightweight frame. It was developed with feedback from factory riders and in hindsight, returns the favor by offering excellent rider feedback.
  1. Engine & Exhaust
  2. Chassis
  3. Ergonomics & Comfort
  4. Bodywork & Graphics
  5. Software & Electronics

01. Engine & Exhaust

Light and powerful
Light and powerful

Engine

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 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.

Cylinder

The KTM 250 XC-W TPI cylinder has a bore of 66.4mm and is fitted with a state-of-the-art power valve providing smooth and controllable power characteristics. For the EFI application the new cylinder features two lateral domes, which hold the fuel injectors supplying fuel into the rear transfer ports. Thus the loss of unburnt fuel is reduced for less emissions, a more efficient combustion and reduced fuel consumption. A tube in the back of the cylinder is connected with an intake pressure sensor, which supplies pressure data to the control unit.

Crankcases and engine covers

For optimal mass centralization the lightweight die-cast crankcases hold the clutch shaft and the crankshaft in a high position close to the center of gravity for quick handling and a light feel. In addition, it allows the implementation of a balancer shaft. So your ride will be as relaxed as it is rapid. Plus, your new favorite engine will keep looking as fresh as the day you bought it: the engine covers feature a surface structure that reduces the wear caused by the rider’s boots.

Transmission

The robust 6-speed transmission made by PANKL Racing Systems features an Enduro-specific wide-ratio specification and provides precise and easy shifting. An advanced ´No Dirt´ gear shift lever design prevents mud and dirt 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 while the 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.

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 250 XC-W TPI 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 durability is as well. Light operation and telepathic amounts of control are standard with this hydraulic Brembo actuated clutch.

Oil pump

Pre-mixing 2-stroke fuel is a thing of the past for KTM XC-W TPI owners. An electronic oil pump feeds oil from the oil tank via the throttle body into the engine intake, and ensures a perfect fuel-oil mix in all conditions and engine speeds. The system, which reduces up to 50% of the smoke from the exhaust system over carburettor models, is managed by the control unit based on the engine’s revs and load measured by the TPS (throttle position sensor). The oil capacity of approximately 0.7 liters is enough for 5-6 refills of fuel, giving you more time to ride, less time measuring things out.

Throttle body

The TPI engine is fitted with a 39 mm 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, while a bypass screw allows the regulation of the idle speed. The cold start device also opens a bypass supplying more air. Via an oil intake tube oil supplied from the oil pump is mixed with the incoming air to lubricate crankshaft bearings and cylinder/piston etc.

TPI Alternator

Always optimal
Always optimal

Cooling

Maintaining the optimal engine temperature is crucial to ensuring consistent horsepower throughout the ride. The KTM 300 XC-W TPI features radiators which are mounted close to the center of gravity and match the design of the shrouds perfectly, in order to achieve perfect ergonomics. The additional KTM PowerParts radiator fan is regulated by the EMS control unit for easy installation. Thanks to flow optimized internal circulation and CFD-calculated ventilation, the system is superbly efficient. In addition the radiator protectors improve heat dissipation. Especially in the mud. They are also integrated into the front part of the shrouds to protect the radiators in a crash.

Shaped for performance
Shaped for performance

Exhaust

When it comes to power delivery and performance, the exhaust plays a key role and packs a punch that is hard to beat. The 250 cc and 300 cc models feature HD exhaust pipes (heavy-duty) made by using an innovative 3D stamping process which produces a ribbed surface finish. This makes the pipe much stronger, with better resistance against rocks, while also helping to reduce noise drastically. The silencer features a compact shape and end cap with internal designs individually developed for each model, while it is mounted using an aluminum mounting bracket. In addition, the exhaust's shape provides slim ergonomics and more ground clearance, while a perforated inner silencer tube works with lighter damping material for efficient and durable noise reduction.

Light and powerful
Light and powerful

Engine

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 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.

Light and powerful

Cylinder

The KTM 250 XC-W TPI cylinder has a bore of 66.4mm and is fitted with a state-of-the-art power valve providing smooth and controllable power characteristics. For the EFI application the new cylinder features two lateral domes, which hold the fuel injectors supplying fuel into the rear transfer ports. Thus the loss of unburnt fuel is reduced for less emissions, a more efficient combustion and reduced fuel consumption. A tube in the back of the cylinder is connected with an intake pressure sensor, which supplies pressure data to the control unit.

Crankcases and engine covers

For optimal mass centralization the lightweight die-cast crankcases hold the clutch shaft and the crankshaft in a high position close to the center of gravity for quick handling and a light feel. In addition, it allows the implementation of a balancer shaft. So your ride will be as relaxed as it is rapid. Plus, your new favorite engine will keep looking as fresh as the day you bought it: the engine covers feature a surface structure that reduces the wear caused by the rider’s boots.

Transmission

The robust 6-speed transmission made by PANKL Racing Systems features an Enduro-specific wide-ratio specification and provides precise and easy shifting. An advanced ´No Dirt´ gear shift lever design prevents mud and dirt 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 while the 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.

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 250 XC-W TPI 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 durability is as well. Light operation and telepathic amounts of control are standard with this hydraulic Brembo actuated clutch.

Oil pump

Pre-mixing 2-stroke fuel is a thing of the past for KTM XC-W TPI owners. An electronic oil pump feeds oil from the oil tank via the throttle body into the engine intake, and ensures a perfect fuel-oil mix in all conditions and engine speeds. The system, which reduces up to 50% of the smoke from the exhaust system over carburettor models, is managed by the control unit based on the engine’s revs and load measured by the TPS (throttle position sensor). The oil capacity of approximately 0.7 liters is enough for 5-6 refills of fuel, giving you more time to ride, less time measuring things out.

Throttle body

The TPI engine is fitted with a 39 mm 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, while a bypass screw allows the regulation of the idle speed. The cold start device also opens a bypass supplying more air. Via an oil intake tube oil supplied from the oil pump is mixed with the incoming air to lubricate crankshaft bearings and cylinder/piston etc.

TPI Alternator

Always optimal
Always optimal

Cooling

Maintaining the optimal engine temperature is crucial to ensuring consistent horsepower throughout the ride. The KTM 300 XC-W TPI features radiators which are mounted close to the center of gravity and match the design of the shrouds perfectly, in order to achieve perfect ergonomics. The additional KTM PowerParts radiator fan is regulated by the EMS control unit for easy installation. Thanks to flow optimized internal circulation and CFD-calculated ventilation, the system is superbly efficient. In addition the radiator protectors improve heat dissipation. Especially in the mud. They are also integrated into the front part of the shrouds to protect the radiators in a crash.

Always optimal
Shaped for performance
Shaped for performance

Exhaust

When it comes to power delivery and performance, the exhaust plays a key role and packs a punch that is hard to beat. The 250 cc and 300 cc models feature HD exhaust pipes (heavy-duty) made by using an innovative 3D stamping process which produces a ribbed surface finish. This makes the pipe much stronger, with better resistance against rocks, while also helping to reduce noise drastically. The silencer features a compact shape and end cap with internal designs individually developed for each model, while it is mounted using an aluminum mounting bracket. In addition, the exhaust's shape provides slim ergonomics and more ground clearance, while a perforated inner silencer tube works with lighter damping material for efficient and durable noise reduction.

Shaped for performance

02. Chassis

Optimal control
Optimal control

Frame

The high-tech, lightweight chrome-moly steel frame has a knack for easy handling, outlandish rideability, precise cornering and excellent stability. You can also count on high torsional rigidity and low longitudinal stiffness. This results in better absorption of the energy created from the front and rear suspension, sucking up jumps and bumps. In short: more comfort and less rider fatigue. Laterally attached, lightweight engine head stays (the connection between cylinder head and frame) contribute to a low vibration level. In addition, it is easy to maintain and to work on and supplies ample space for the tank and other components. On the XC-W TPI models the upper frame tube features a slot where the oil filler cap is mounted, which feeds the oil tank via a hose inside the frame tube. The bike also features an extra-light subframe made of aluminum, which tiptoes the scales at less than 2 pounds.

Swingarm

The cast aluminum design offers low weight and a perfect flex behavior. The single-component casting process eliminates any inconsistencies and inherent weak points created by welding. It’s good looking as well.

Wheels

The XC-W wheels feature lightweight, CNC machined hubs and high-end Giant rims guaranteeing maximum stability at minimum weight. The wheels are fitted with Dunlop AT 81 tires – perfect for surefooted performance offroad.

Front suspension

All XC-W models are fitted with the latest 48 mm diameter WP XPLOR upside-down forks, featuring a split fork design developed by WP and 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). Although already distinguished for outstanding response and damping characteristics, the fork features a calibrated mid-valve piston for consistent damping. The settings keep the front end higher in the stroke, providing impressive reserves against bottoming out.

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. The progressive damping is achieved by a second piston, which works together with a closed cup towards the end of the stroke. This design contributes to an optimal progression behavior of the damping supported by a progressive shock spring. 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 250 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.

Superior braking feel
Superior braking feel

Brakes

You couldn’t brake any harder, better, faster or stronger. These high-tech Brembo brakes are combined with lightweight Wave brake discs and are the ultimate solution in braking technology. First you outrun them, then you outbrake them.

Simple and effective
Simple and effective

Fuel tank

This is a lightweight polyethylene tank with a capacity of 2.4 gallons. Manufactured using see‐through plastic, you will always be able to see how much fuel remains at a glance. Additionally, the XC-W TPI models incorporate an integrated fuel pump system and an additional fuel level sensor so you'll always know when you're running low on gas.

Simple and effective

Airbox

The air filter box design offers maximum protection of the air filter against soiling, while ensuring maximum airflow, and together with the intake snorkels, results in optimal power and throttle response. The large Twin Air air filter is mounted on a stiff cage, which at the same time holds the system in place. This design is so simple, you could still pop a fresh one in with a face full of mud. Without tools. In seconds.

Optimal control
Optimal control

Frame

The high-tech, lightweight chrome-moly steel frame has a knack for easy handling, outlandish rideability, precise cornering and excellent stability. You can also count on high torsional rigidity and low longitudinal stiffness. This results in better absorption of the energy created from the front and rear suspension, sucking up jumps and bumps. In short: more comfort and less rider fatigue. Laterally attached, lightweight engine head stays (the connection between cylinder head and frame) contribute to a low vibration level. In addition, it is easy to maintain and to work on and supplies ample space for the tank and other components. On the XC-W TPI models the upper frame tube features a slot where the oil filler cap is mounted, which feeds the oil tank via a hose inside the frame tube. The bike also features an extra-light subframe made of aluminum, which tiptoes the scales at less than 2 pounds.

Optimal control

Swingarm

The cast aluminum design offers low weight and a perfect flex behavior. The single-component casting process eliminates any inconsistencies and inherent weak points created by welding. It’s good looking as well.

Wheels

The XC-W wheels feature lightweight, CNC machined hubs and high-end Giant rims guaranteeing maximum stability at minimum weight. The wheels are fitted with Dunlop AT 81 tires – perfect for surefooted performance offroad.

Front suspension

All XC-W models are fitted with the latest 48 mm diameter WP XPLOR upside-down forks, featuring a split fork design developed by WP and 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). Although already distinguished for outstanding response and damping characteristics, the fork features a calibrated mid-valve piston for consistent damping. The settings keep the front end higher in the stroke, providing impressive reserves against bottoming out.

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. The progressive damping is achieved by a second piston, which works together with a closed cup towards the end of the stroke. This design contributes to an optimal progression behavior of the damping supported by a progressive shock spring. 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 250 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.

Superior braking feel
Superior braking feel

Brakes

You couldn’t brake any harder, better, faster or stronger. These high-tech Brembo brakes are combined with lightweight Wave brake discs and are the ultimate solution in braking technology. First you outrun them, then you outbrake them.

Superior braking feel
Simple and effective
Simple and effective

Fuel tank

This is a lightweight polyethylene tank with a capacity of 2.4 gallons. Manufactured using see‐through plastic, you will always be able to see how much fuel remains at a glance. Additionally, the XC-W TPI models incorporate an integrated fuel pump system and an additional fuel level sensor so you'll always know when you're running low on gas.

Simple and effective
Simple and effective

Airbox

The air filter box design offers maximum protection of the air filter against soiling, while ensuring maximum airflow, and together with the intake snorkels, results in optimal power and throttle response. The large Twin Air air filter is mounted on a stiff cage, which at the same time holds the system in place. This design is so simple, you could still pop a fresh one in with a face full of mud. Without tools. In seconds.

03. Ergonomics & Comfort

Centralized control
Centralized control

Handlebar

KTM engineers sure know how to handle handlebars. This tapered unit, made of high-strength aluminum by NEKEN, features a throttle assembly which has a twin-cable for TPI models just like their 4-stroke brothers with a double-cable aluminum body and straightforward free-play adjustment. A vulcanized grip sits on the right, while on the left side of the bar a comfortable ODI lock-on grip is mounted, which does not require any wire or glue to be fixed.

Innovative engineering
Innovative engineering

Footpegs

Sophisticated ´No Dirt´ footpegs prevent jamming up the pegs, even when digging in deep ruts. The pegs on the Cross Country models are 6mm higher than the ones used on SX models, which benefits ground clearance. But you can swap them at will.

Supreme manoeuvrability
Supreme manoeuvrability

Seat

The XC-W range features state-of-the-art seat technology with a newly shaped surface that provides improved ergonomics and much better seat comfort thanks to higher foam padding. The seat is conveniently fixed to the bike using one long, lateral screw, making it safe and easy to handle.

Centralized control
Centralized control

Handlebar

KTM engineers sure know how to handle handlebars. This tapered unit, made of high-strength aluminum by NEKEN, features a throttle assembly which has a twin-cable for TPI models just like their 4-stroke brothers with a double-cable aluminum body and straightforward free-play adjustment. A vulcanized grip sits on the right, while on the left side of the bar a comfortable ODI lock-on grip is mounted, which does not require any wire or glue to be fixed.

Centralized control
Innovative engineering
Innovative engineering

Footpegs

Sophisticated ´No Dirt´ footpegs prevent jamming up the pegs, even when digging in deep ruts. The pegs on the Cross Country models are 6mm higher than the ones used on SX models, which benefits ground clearance. But you can swap them at will.

Innovative engineering
Supreme manoeuvrability
Supreme manoeuvrability

Seat

The XC-W range features state-of-the-art seat technology with a newly shaped surface that provides improved ergonomics and much better seat comfort thanks to higher foam padding. The seat is conveniently fixed to the bike using one long, lateral screw, making it safe and easy to handle.

Supreme manoeuvrability

04. Bodywork & Graphics

Aggressively styled
Aggressively styled

Decals

The durable in-mold graphics convey the READY TO RACE character of the KTM XC-W model line.

Aggressively styled
Aggressively styled

Decals

The durable in-mold graphics convey the READY TO RACE character of the KTM XC-W model line.

Aggressively styled

05. Software & Electronics

Easy starting

Battery & wiring harness

A strong lithium ion battery breathes life into the engine and contributes to low vehicle weight. The lightweight battery and wiring harness are centralized in a compartment above the air filter box, allowing the mechanic to remove the subframe without removing the electronics. A happy mechanic is a good mechanic.

Easy starting

Battery & wiring harness

A strong lithium ion battery breathes life into the engine and contributes to low vehicle weight. The lightweight battery and wiring harness are centralized in a compartment above the air filter box, allowing the mechanic to remove the subframe without removing the electronics. A happy mechanic is a good mechanic.

Technical Details

Engine

  • Transmission 6-speed
  • Starter Electric starter
  • Stroke 72 mm
  • Bore 66.4 mm
  • Clutch wet multi-disc clutch, Brembo hydraulics
  • Displacement 249 cm³
  • EMS Continental EMS
  • Design 1-cylinder, 2-stroke engine

Chassis

  • Weight (without fuel) 103.4 kg
  • Tank capacity (approx.) 9 l
  • Front brake disc diameter 260 mm
  • Rear brake disc diameter 220 mm
  • Front brake Disc brake
  • Rear brake Disc brake
  • Chain X-Ring 5/8 x 1/4"
  • Frame design Central double-cradle-type 25CrMo4 steel
  • Front suspension WP XPLOR-USD, Ø 48 mm
  • Ground clearance 370 mm
  • Rear suspension WP Xplor PDS shock absorber
  • Seat height 950 mm
  • Steering head angle 63.5 °
  • Suspension travel (front) 300 mm
  • Suspension travel (rear) 310 mm