Motorcycle specifications KTM150 EXC TPI 2020 The morning challenge

Completely overhauled in its 2020 version, the queen of extreme enduro can now count on TPI fuel injection to comply with the very strict Euro IV standard. No more premixing fuel and no more manual intervention by the rider to fine-tune the bike's carburation! Easier to ride and maintain than ever, this off-road virtuoso is ready to let the lightning strike. Already renowned for its incredible agility, the new KTM 150 EXC TPI benefits from an all-new, more flexible frame, as well as numerous other improvements that will enable rider and mount to express their full potential.

engine and silencer

kTM's vast range of 2-stroke off-road competition bikes is a veritable technological showcase for the brand. Two years after the introduction of the world's first 2-stroke off-road motorcycles to feature electronic fuel injection, KTM is once again causing a stir with its competition engines. a new generation of off-road competition engines, featuring a revolutionary TPI system. The 150 EXC, the latest addition to an already well-stocked range, proves just how much KTM believes in the future of 2-stroke technology. The advantages are obvious: in addition to the significant reduction in fuel consumption and pollutant emissions, this system eliminates the need for fuel premixes and manual intervention by the rider to fine-tune the bike's carburation. As a result, the engine can deliver its full potential, whatever the circumstances.

engine

the 150 cm3 2-stroke engine has been extensively modified for the 2020 models. Thanks to the engineering solutions implemented, its innovative 2-stroke technology and revolutionary TPI injection system, the 2020 version of this block is more civilized than ever, delivering uncommon power across the rev range. The improvements made to this compact, lightweight 2-stroke provide an extra level of efficiency and handling that will delight hard-core enduro riders.

cylinder

the cylinder of the 150 EXC TPI, with its 58 mm bore, benefits from perfectly synchronized exhaust ports and a sophisticated exhaust valve control system, ensuring smooth power delivery. The injectors responsible for introducing fuel into the rear transfers are positioned on either side of the cylinder. Downward injection offers the advantage of excellent atomization with rising air. Combustion is therefore more efficient, resulting in fuel savings and lower emissions. A small tube at the rear of the cylinder is connected to the intake pressure sensor, which communicates the air flow to the control unit. The cylinder features state-of-the-art exhaust valve control and a sophisticated mechanism for the side exhaust outlets. The configuration of the exhaust outlets contributes to enhancing engine performance. The upper contour of these components has even been machined to ensure ultra-precise timing. The new cylinder, featuring TPI technology, guarantees optimum performance throughout the rev range, and delivers far more torque than its predecessor. Last but not least, this new version allows the use of a more common type of conventional spark plug.

crankcases and covers

the use of a high-pressure die-casting process has resulted in a relatively compact crankcase that is even lighter, while maintaining its strength and durability. The design of the crankcase has enabled KTM engineers to move the shaft mounts closer to the center of gravity, so as to better centralize the masses and enhance rideability. The 2020 model features a new alternator housing to accommodate the larger alternator. Another interesting innovation to keep this EXC's engine as radiant as in the early days: crankcase covers with an elaborate surface structure, designed to reduce wear caused by the rider's boots.

gearbox

the 150 EXC TPI is now equipped with a new, more robust 6-speed gearbox, manufactured by PANKL RACING SYSTEMS. The transmission ratios of the previous version have been retained, but the sprockets have all been improved and reinforced. Instead of using a circlip to secure the front sprocket, the new balance shaft is now immobilized by a bolt and diaphragm spring, as on all other KTM offroad models. This guarantees greater reliability. Another highlight of the gearbox on the KTM 150 EXC TPI is the "zero dirt" design of the selector. Designed on the same principle as the footrest, it prevents the accumulation of dust and enables the gearbox to remain operational in all conditions.

engine management

the engine management system (EMS) on TPI models features a control unit located under the seat. Ignition timing is calculated by the ECU. The precise amount of fuel to be injected depends on sensor readings such as intake air pressure, throttle position and water temperature. Ambient air pressure is also taken into account. As the system is designed to compensate for altitude and temperature fluctuations, injection requires no manual intervention on the part of the pilot. Should the rider decide to fit a cooling fan (available in the KTM PowerParts catalog), it will be placed under the direct control of the engine management system (EMS) without the need for an additional thermocontact. An optional map selector can be purchased to change engine modes on the fly and adapt power delivery to conditions.

clutch

the 150 EXC TPI inherits a DS (Diaphragm Steel) clutch. It consists of a one-piece clutch housing and a main gear (made of high-strength billet steel). Its compact, rivet-free design guarantees unrivalled reliability. The clutch is fitted with extremely heat-resistant steel engine friction discs (to optimize clutch disengagement) and preloaded by a diaphragm spring (to significantly reduce the force exerted on the lever with the Brembo hydraulic system).

oil pump

eXC TPI owners can now do without the traditional 2-stroke oil/fuel premixing. The 2-stroke oil tank has been redesigned for 2020 models. The mounting system is more flexible than before, for even greater durability and reliability. A sieve has also been added to prevent impurities from entering the oil pump. The oil drawn by the oil pump (mounted beneath the oil reservoir) passes through the injection body, where it is mixed with incoming air to lubricate the piston and crankshaft. Based on engine speed and data from the throttle valve position sensor, the Engine Management System (EMS) central electronic control unit (ECU) determines the ideal quantity of oil to use, according to current conditions. The oil filler cap, located between the fuel tank and the steering column, feeds the oil tank via a hose in the upper part of the frame tube. With an average fuel-oil ratio of 1:80, the tank has enough capacity (0.7 liters) for at least five fill-ups.

injection unit

the TPI injection engine features a new 39mm throttle body developed by Dell`Orto. The amount of air entering the engine is regulated by a throttle linked to a cam (with two cables) controlled by the handlebar throttle. In addition, a throttle valve position sensor communicates air flow to the control unit. On 2020 models, idle speed can be fine-tuned using the bypass screw. The cold-start device opens a bypass circuit to supply the extra fuel required for cold starts. The oil supplied by the electronic oil pump passes through the intake pipe before being mixed with the incoming air to lubricate the engine's moving parts.

tPI alternator

to meet the energy requirements of the new engine management system (EMS), TPI models are equipped with a TPI alternator.models are equipped with a voltage regulator and a generator capable of supplying 196 W (the same as on EXC-F 4-stroke models).

cooling

to ensure smooth power delivery, it's essential to maintain optimum engine temperature. To this end, the 150 EXC TPI features new radiators, 12 mm lower than its predecessor. This position, perfectly matched to the design of the new spoilers, lowers the center of gravity and enhances ergonomics. Thanks to CFD (Computational Fluid Dynamics) and a clever cooling circuit, this innovative system ensures that engine components are kept at the ideal temperature to guarantee the highest level of performance, whatever the conditions. To ensure more efficient circulation of coolant between the cylinder head and the radiators, the diameter of the central tube of the exhaust pipe (integrated into the frame wishbone) has been increased by 4 mm, representing a 57% increase in flow cross-section. Special radiator guards not only protect the radiators from stones and other debris, but also distribute the force of impact around them.

muffler

the new exhaust system gives the engine a smoothness and liveliness that are hard to match. The optimized shape of the muffler has been designed using an ultra-modern three-dimensional stamping process. The silencer benefits from a perforated inner tube and lighter insulating material (wool). Working in perfect harmony with the new exhaust, the TPI engine offers a significant performance gain at low revs compared to the previous carburettor model, making it all the more suitable for enduro riding. The muffler's plastic mounting system has been replaced by 2 welded aluminum brackets, saving 60 grams.

chassis

to be truly competitive, a 2-stroke enduro bike has to be light. So it's no surprise that the 150 EXC TPI is one of the lightest, slimmest and most agile enduro bikes in its class.

frame

all EXC models feature a new high-tech lightweight chromoly steel frame, made of hydroformed tubes assembled by automated welding. Engineers retained the competition-proven geometry, but reworked certain parts of the frame to optimize rigidity. The ultimate aim was to improve rider feedback, agility and stability. The lugs connecting the cylinder head to the frame are now made of aluminum. Mounted laterally, they help limit vibration levels and refine the bike's trajectory in corners. The new side frame protectors feature a structured surface for improved grip. They also protect the rider from the heat generated by the muffler on the right-hand side. The rear buckle is made of ultra-light, stable aluminum sections, longer (40 mm more) and lighter (900 grs less) than before, designed to reinforce the stability of the rear shell.

swingarm

the 150 EXC TPI's new aluminum monoblock swingarm, produced by high-pressure die-casting, has been designed to offer rock-solid strength, while keeping weight to an absolute minimum. The monoblock casting process not only optimizes bending behavior and material weight, but also allows a wide range of geometries.

wheels

featuring ultra-light CNC-machined hubs and top-of-the-range GIANT rims, the wheels on all Enduro models guarantee maximum stability despite limited weight. The aluminum spoke nipples on 2020 models have been redesigned to reduce the frequency with which spokes need to be re-tensioned.

front suspension

all EXC models inherit the latest WP XPLOR USD fork with separate damping circuits (48 mm in diameter), designed by WP and KTM. Although both fork arms are equipped with springs, their functions differ. The left arm handles compression damping, while the right arm handles rebound. To fine-tune each of these settings, simply turn the 30-notch knob above each fork tube. Although this fork is already renowned for its sensitivity and efficiency, it features a perfectly calibrated floating piston for even more even damping on the 2020 model. New fork top caps and new, more intuitive adjustment knobs, with new colors and graphics, are also featured. The rider also benefits from new settings to raise the front axle for greater resistance to bottoming.

rear suspension

an essential component of the proven PDS rear suspension, the WP XPLOR shock absorber is connected directly to the swingarm, without the need for an additional linkage system. In addition to saving weight, this solution reduces the risk of snagging on large stones. To ensure optimum progressiveness of the enduro-specific damping, a second piston is combined with a cup-shaped end-stop and supported by a progressive-action spring. To increase resistance to bottoming without sacrificing comfort on the 2020 model, the second piston has been redesigned, and the sealing and shape of the end stop have been optimized. New XPLOR PDS shock absorber settings, specific to the new frame and front-end configuration, improve damping characteristics. Fully adjustable, including high-speed and low-speed compression, this shock absorber can be adapted to suit track conditions or rider preferences.

brakes

brembo brakes, small jewels of technology, are combined with Wave brake discs renowned for their lightness. Rarely has an off-road motorcycle offered such an efficient braking feel.

fuel tank

all EXC models feature a new, ultra-light, ergonomic polyethylene fuel tank. The bayonet-type quarter-turn cap eliminates time-consuming resealing of the tank. As the tank is made of transparent plastic, you can see how much fuel is left at a glance. This model features an integrated fuel pump system and fuel level indicator. The 90-degree fuel line connection further protects the tank from damage.

air filter housing

the new air filter housing on the 150 EXC TPI has been completely redesigned to take account of the new TPI injection body and optimize flow dynamics. Combined with the new intake snorkels, it ensures exceptional power delivery and acceleration. In addition to the obvious performance gains, the new design also protects the air filter from clogging. The rigid support for the large Twin-Air filter has been designed to minimize installation errors. As on previous models, the filter can be serviced in record time and without tools, a typically KTM feature.

ergonomics and comfort

kTM has drawn on its long experience and decades of racing success to perfect the ergonomics of the 150 EXC TPI and create the perfect osmosis between man and machine. This gives the rider total freedom of movement and optimum comfort, whatever the conditions. The rear light has also been redesigned to match the new shape of the rear hull and front cross plate holder.

handlebars

all EXC models feature the same ultra-strong, profiled aluminum handlebars made by NEKEN. These can be adjusted to four different positions. right: an ODI vulcanized handlebar grip available as standard; left: an ODI lock-on handlebar grip that's as comfortable as it is practical, thanks to its glue- and wire-free mounting system. All models can also be fitted with an optional handlebar-mounted map selector for switching between Standard and Advanced power curves.

footrests

sophisticated "zero-dirt" footrests prevent the gear selector from fouling, even when passing through deep ruts. To enhance ground clearance, the gear selector on Enduro models is 6 mm higher than on SX models.

saddle

the saddle of the EXC 2020 motorcycle range has a more ergonomic shape. It also benefits from even more comfortable foam padding. A long screw inserted into the side of the saddle helps secure it to the motorcycle, making handling easier and safer.

cladding and graphics

the front and rear shells have a special, stiffer shape that guarantees maximum stability (even at high speeds). Better still, they stay clean longer thanks to an innovative design that expels mud and dirt. The clever mounting of the brake hose on the cross front plate also reduces wear due to friction.

software and electronics

eXC TPI models feature one of the most advanced engine management systems ever designed for a 2-stroke enduro. Ignition timing is calculated by the control unit (ECU). The precise amount of fuel to be injected depends on sensor readings such as ambient and intake air pressure, throttle position and water temperature.

battery and wiring harness

all engines are equipped with the tried-and-tested electric starter, a major off-road asset. To start the engine every time, the starter is powered by an ultra-lightweight 2 Ah lithium-ion battery. The wiring harness has been optimized. Most of the electrical components are grouped together under the seat, for easier access and greater reliability.

Information and image credits: KTM