DDS CLUTCH

The 250 XCF-W has a DDS (damped diaphragm steel) design with a wear-resistant clutch basket, which has been revised for MY 2015 for weight saving, and operates with a diaphragm spring. The basket is machined from high-tensile steel in one piece together with the primary drive gear. This process provides unbeatable reliability and contributes to the narrow engine width thanks to its compact rivet-less design, as well as thin steel linings that assist with the compact clutch dimensions. The diaphragm spring makes it possible to implement an additional rubber damping system inside the clutch hub that offers reliability for the transmission and good traction. This, combined with the hydraulic clutch mechanism by Brembo, provides a very light operation and good controllable modulation of the clutch.

COUNTER BALANCER

In order to balance the mass-forces, the 250 XCF-W engine uses a multifunctional counter balance shaft which also drives the water pump and timing chain.

TRANSMISSION

Specially developed for the 250, the six-speed enduro gearbox has comparatively short gear ratios in fourth and fifth, as well as a new longer overdrive sixth gear. The transmission is renowned for its easy and precise shifting.

CRANKSHAFT

The 250 XCF-W’s crankshaft has a flywheel that is designed to achieve optimum traction. The crankshaft itself employs a plain big end bearing, while two force-fitted bearing shells run directly on the crank pin. The necessary oil feed for this bearing is delivered by the engine’s pressure lubrication. This design increases the engine’s long-term durability, lengthening crankshaft service intervals, which is a customer benefit.

CRANKCASE

A completely new crankcase design, which is now pressure die-cast allows to reduce the wall thicknesses significantly, compared to cases produced by gravity die-cast. A new aluminum alloy which at the same time has great tensile strength ensures a high resilience against stone-chipping and other damage.

ENGINE

The smallest of the KTM four-stroke range, which is liked for its strong engine combined with its agile, flickable chassis characteristics. The compact and powerful engine, along with the very maneuverable chassis, remain unchanged for MY 2015.

STARTER

The new 250 XCF-W engine can be started with a kickstarter as well as an electric starter. Well protected behind the cylinder, the electric starter is connected to the starter freewheel on the ignition rotor via the starter drive in the ignition cover.

ENGINE MANAGEMENT SYSTEM (EMS)

The Engine Management System by Keihin with electronic fuel injection and a 42mm throttle body ensures a spontaneous response and maximum engine performance. An oil-cooled 196W AC alternator provides sufficient energy for the fuel injection, lighting and other electrical loads, while the efficient ECU offers fast and reliable data processing.

CYLINDER HEAD

The centerpiece of the KTM XCF-W DOHC (Double overhead camshaft) engine is the cylinder head with two overhead camshafts and DLC coated followers, which are ultra-lightweight. The large, flow optimized ports in combination with large intake valves offer a perfected flow rate to deliver significant performance. The camshafts have been designed to achieve maximum power and torque, while maintaining a power delivery suited to enduro riding. The engine boasts lightweight titanium valves and followers for low oscillating masses along with high rpm.