The engine of the 150 SX is well-known as the most powerful and most competitive engine of the class. However, it is time to give a new push to the segment and set a clear statement that two-stroke technology is going to have a successful future due to its outstanding power-to-weight ratio, low cost and simplicity. The newly developed 150 cm³ engine for MY 2016 features a completely new architecture with the latest know-how and state-of-the-art technology. The result is that it produces better power all over the rev range, it’s more than 2 kg lighter than the predecessor and it is much more compact.
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Engine
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 Cylinder
Within the heart of the new engine is a newly designed cylinder with reworked ports and a newly developed power valve unit with a sophisticated mechanism for the lateral support exhaust ports. Together with a new two-component cylinder head, a massive performance increase over the entire range has been achieved. Even though it is 0.8 lb lighter and more compact than the previous model, the new layout of the water jackets in the cylinder and head guarantee a better heat dissipation, keeping the 150 SX cool under the most extreme conditions.
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Clutch
The new engine features a new hydraulic clutch mechanism made by Brembo instead of Magura. It ensures an easy clutch action and well-defined modulation.
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 Die-cast engine cases
For the latest 2-Stroke engine generation the KTM engineers designed all new die-cast engine cases featuring a 27 mm higher clutch shaft and 37 mm higher crankshaft position, which results in better mass centralization for improved rideability. In addition, the engine itself is much more compact and this contributes massively to the weight reduction of 1.3 lbs.
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Transmission
A new 6-speed transmission provides the same gear ratios as the previous model, but due to the latest production technologies the width could be reduced by 6 mm and the weight reduced by 200 g. An advanced "NO-DIRT" gear lever design prevents dirt from blocking the joint of the lever guaranteeing safe activation of the transmission. |
Piston
For the latest 2-Stroke engine generation the KTM engineers designed all new die-cast engine cases featuring a 27 mm higher clutch shaft and 37 mm higher crankshaft position, which results in better mass centralization for improved rideability. In addition, the engine itself is much more compact and this contributes massively to the weight reduction of 1.3 lbs. |
Exhaust
For the new model our engineers developed a new, specifically tuned exhaust pipe in order to get the maximum power output of the engine. |
New crankshaft
For the new model the crankshaft provides the same stroke of 54.5 mm as the 150 cm³ engine and it features an optimized balancing for minimum vibrations and it is 50 g lighter. |
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Massive weight reduction
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 Airbox
The modern frame design of the 250 SX, comprised of lightweight, high strength, chrome-molybdenum steel section tubes, combines maximum longitudinal stiffness with optimum torsional stiffness.
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 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!
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Seat
Ergonomically perfect, the new seat has a higher foam volume, which offers great comfort and durability, while weighing the same as the previous model.
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Newly designed chassis
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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 lighter than the previous model. |
Handlebar
The new generation SX models are equipped with a new tapered handlebar made of high-strength aluminum by NEKEN, which is fixed in a new rubber damped handlebar clamp allowing the handlebar to be mounted in two different positions. |
 Swingarm
As on the predecessor models, the new SX generation features a reworked cast aluminum swingarm. The updated design offers reduced weight and an optimized flex behavior supporting the frame and suspension created with a single-component casting process. The weight reduction is 250 grams.
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 Footpeg
A new sophisticated "No-Dirt" footpeg solution prevents dirt from blocking the pegs and stopping them from returning to the proper position, even when digging in deep ruts. In addition the new footpegs are larger, more stable, lighter than on previous models and offer more grip. |
 Fuel tank
All models of the SX range have new lightweight polythene tanks with a capacity of 1.85 gallons. A filler cap with an inside thread makes for an easy and reliable closure.
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 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.
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 Graphics
New modern in-mold graphics highlight the sporty character of the 2016 SX range of cutting-edge motocross bikes.
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 Cooling system
The proven integrated KTM cooling system routes the coolant from the cylinder head through the frame triangle, directly to newly developed aluminum 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 protection in case of a crash.
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State-of-the-art suspension
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 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 swingarm architecture that includes a reworked linkage system and new WP forks. The linkage system has a revised geometry and longer pull rods, which was tested last season in the KTM factory bikes.
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Forks
The KTM SX 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 precise handling, they provide proper clamping force for correct flex characteristics, thus improving the action of the forks. For 2016 the upper triple clamp features a newly developed rubber damping system for the handlebar clamp in order to reduce the vibration levels felt through the handlebar. The clamps retain their forward and back adjustability for 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 improved handling. The resulting loss of 6.3 lbs is outstanding, making the new KTM models the lightest bikes on the track. |
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Unrivalled handling
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 Wheels
The 150 SX is fitted with lightweight, CNC-machined hubs, high-end Excel rims and new, weight reduced spokes with lightweight aluminum nipples providing maximum stability at minimum weight. The latest Dunlop Geomax MX32 tires have been developed with KTM factory racing in the USA and expert test riders. They guarantee perfect traction and outstanding performance.
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Brakes
High-tech Brembo brakes have always been standard equipment on KTM off-road bikes, and now are combined with newly designed and weight-reduced Wave discs made by GALFER featuring improved heat resistance. Weight reduction is 63g on the front disc, and 32 g for the rear. This is the ultimate solution in braking technology. |
