The KTM 300 EXC TPI ERZBERGRODEO limited edition is a force to be reckoned with – not unlike the Iron Giant itself. This nimble, lightweight all-terrain master fears no obstacle, making it the ultimate extreme enduro machine. Packed with a select series of KTM PowerParts and a unique graphics kit to commemorate this special event, the KTM 300 EXC TPI ERZBERGRODEO is all the enduro motorcycle you will ever need to conquer the world’s most extreme enduro race.
A legend in its own right, the KTM 300 cc 2-stroke engine has long been a favorite when it comes to enduro weaponry. This is largely down to its exceptional power, low-down torque and overall lightweight. Thanks to state-of-the-art engineering, innovative 2-stroke design, and revolutionary TPI fuel injection technology, this powerplant has become a truly refined unit.
The cylinder on the KTM 300 EXC TPI has a bore of 72 mm and is fitted with a sophisticated power valve, providing ultra-smooth and controllable power characteristics. Being fuel-injected, the cylinder features two lateral domes which hold the fuel injectors, supplying 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 fewer emissions, more efficient combustion, and reduced fuel consumption. The cylinder also features a state-of-the-art power valve unit with a sophisticated mechanism for the lateral support exhaust ports. The exhaust port layout increases engine performance, while the upper contour of the exhaust port has been machined to ensure more accurate port timing.
CRANKCASES AND ENGINE COVERS
These compact engine cases are manufactured using a high-pressure die-cast production process which helps with weight reduction but maintains strength and durability. This design also allows for optimal shaft arrangements close to the center of gravity, resulting in ideal mass centralization and ride-ability. The KTM 300 EXC TPI ERZBERGRODEO edition also makes use of a CNC KTM PowerParts oil plug and smart surface structure on the engine covers, meaning it will continue to look as fresh after the race, as it did lining up.
The KTM 300 EXC TPI is makes use of a robust 6-speed transmission made by PANKL RACING SYSTEMS. The gears are made of a strong, forged raw material, ensuring the highest durability and reliability level. Another highlight of the KTM 300 EXC TPI transmission is the no-dirt gear shifter. Similar to the footpeg design, it prevents the build-up of dirt and ensures the next gear is always available, no matter what the conditions.
ENGINE MANAGEMENT SYSTEM
The engine management system (EMS) of all 2-stroke EXC 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, water temperature , and ambient air pressure. Thanks to altitude and temperature compensation, re-jetting is a thing of the past, meaning more time twisting throttles and less time turning screws. Should the rider decide to mount a radiator fan from the KTM PowerParts, it will be controlled directly by the EMS without needing to add an additional thermal switch.
The KTM 300 EXC TPI engine design allows for the implementation of a lateral balancer shaft in order to keep engine vibrations to a minimum. This means riders can focus on the obstacles ahead of them, with out distraction. After all, more comfort equals less fatigue.
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.
Pre-mixing 2-stroke fuel is a thing of the past for KTM EXC TPI owners. The 2-stroke range is fitted with an oil tank featuring 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.
The KTM 300 EXC TPI engine is fitted with a 39 mm throttle body made by Dell`Orto. These regulate the airflow via a butterfly connected with a twin-cable throttle cam, which is operated by the handlebar throttle assembly, supported by a throttle position sensor that provides airflow data to the control unit. What all this means is, riders can precisely set the idle speed via the bypass screw, as well as easier cold starts.
In order to accommodate the power requirements of the engine management system, all KTM TPI models are fitted with a powerful 196 W alternator and voltage regulator to ensure all systems are always powered up.
Keeping the engine cool when the going gets tough comes courtesy of a pair of radiators, mounted close to the center of gravity. These make use of CFD technology (Computational Fluid Dynamics) and clever coolant circuit routing, achieving optimum engine temperature for the highest performance, in all conditions. Above all, the delta distributor, integrated into the frame triangle, features a large center tube for highly efficient coolant flow. The radiators also benefit from plastic protection fins 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.
There’s more to it than ‘braaaap!’. The exhaust plays a key role in packing that signature 2-stroke punch. All KTM 300 EXC TPI models feature heavy-duty exhaust headers made using an innovative 3D stamping process that produces a ribbed surface finish. This makes the pipe much stronger, with better impact resistance, while also helping to reduce noise. The silencer features a compact shape and end cap with internal designs individually developed for each model and mounted using an aluminum bracket for strength. In addition, the exhaust’s overall shape provides a slim profile resulting in improved ground clearance, while a perforated inner silencer tube uses lightweight damping material for efficient and durable noise reduction.
All KTM EXC models feature high-tech, lightweight Chromoly steel frames with race-derived geometry, optimal stiffness, and unparalleled feedback for the rider. This translates into a playful handling character, with remarkable stability at speed. The subframe is made of extra-light and ultra-stable aluminum profiles, weighing less than 900 grams providing rear fender stability and durability in the event of a loop out.
The KTM 300 EXC TPI ERZBERGRODEO features a one-piece aluminum swingarm, which is manufactured using a gravity die-cast production process. This results in exeptional strength at the lowest possible weight and the perfect flex behavior.
The KTM 300 EXC TPI ERZBERGRODEO edition makes use of the highest quality CNC machined factory wheels with anodized orange hubs. Besides looking the part, these wheels keep the weight down. And thanks to a set of Metzeler 6 DAYS EXTREME rubber, even in the toughest, most slippery conditions are dispatched effortlessly.
New, race-specification, puncture-resistant MAXXIS MaxxEnduro are designed for all-day riding comfort, with extreme grip and performance across any terrain.
The KTM 300 EXC TPI ERZBERGRODEO is fitted with the latest 48 mm diameter WP XPLOR upside-down forks. For 2022, these have undergone a small update, with refined firmer factory settings focussed on performance, as well as new slots in the outer fork tube, which feed more oil to the bushes and reduce friction and heat build-up. The fork springs have also been updated with a polished surface finish, which improves consistency as well as wear resistance. A new valve design also improves rebound damping performance. The forks retain their adjustability, with compression damping on the left and rebound on the right. The ERZBERGRODEO edition also comes with CNC machined triple clamps that combine perfectly with the WP XPLOR fork.
The race-proven and fully adjustable WP XPLOR shock absorber has received a re-tune, with factory settings making it firmer, and new conical bushing between the pistons to improve bottoming reserves. This has resulted in reduced fade and improved wear, taking the PDS rear suspension design even further in its quest for podiums.
Made to conquer the long downhill drops at the Iron Giant, these high-tech Brembo brakes are combined with lightweight wave brake discs, including a solid disk on the rear for maximum feel and ultimate stopping power. The KTM 300 EXC TPI ERZBERGRODEO edition also provides extra brake protection with a front and rear brake-disc guard, as well as a rear brake safety wire as standard.
All KTM enduro models are fitted with lightweight polyethylene tank, with a ¼-turn bayonet-style filler cap makes for quick and easy operation. The integrated fuel pump ensures a direct feed to the injectors, while a 90° connector provides protection against damage. The tank is also manufactured using see-through plastic, riders are able to gauge fuel levels at a glance and on the go.
The easy-access airbox on the KTM 300 EXC TPI ERZBERGRODEO ensures optimal flow dynamics, thanks to specially designed intake snorkels. This means air is force-fed into the motor, resulting in the perfect balance of power and throttle response. Keeping the air clean, is a large Twin-Air air filter fitted to a rigid cage for ideal placement at all times.
All KTM EXC models are equipped with adjustable, high-strength aluminum tapered handlebars made by NEKEN. These can be mounted in four different positions. Standard with ODI vulcanized grip on the right side and a comfortable ODI lock-on grip on the left, your only worry is hanging on, and letting rip. Additionally, the KTM 300 EXC TPI ERZBERGRODEO is equipped with a handlebar map select switch, which lets you select between a standard and advanced power curve.
Self-cleaning footpegs prevent mud from clogging up the pegs, even when dragging them through deep ruts. This means your boots maintain their grip, and you maintain your focus on the trail.
BATTERY AND WIRING HARNESS
The KTM 300 EXC TPI ERZBERGRODEO is fitted with a time-proven electrical system, powered by a super lightweight 2 Ah lithium-ion starter battery. The wiring harness also has most of the electrical components carefully positioned into a common area below the seat, making them easily accessible.