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The 2005 KTM Motorcycle Range

KTM 450 EXC KTM 640 LC4 Adventure KTM 950 SM KTM Superduke 990 KTM 65 SX KTM 450 SMR Buell 950 Adventure KTM 640 LC4 Enduro KTM 250 EXC KTM 450 SX KTM 950 Adventure S KTM 640 LC4 SM Enduro

The brand-specific product use that KTM street motorcycles stand for defines itself with exceptional, groundbreaking handling and an excellent power-to-weight ratio. The subsequent "950 Supermoto" and "RC8" models, being presented as pre-production models, underline this direction.

Further expanding KTM's leading position in the offroad segment is the second focus point. The 2005 model range is shaped by the consistent further development of the engines and chassis. At the same time our experience and knowledge gained from factory racing has been incorporated directly into the series models, following our successful product philosophy - "Ready to Race". KTM again looks back on a successful business year.

SPORTMINICYCLES MODELRANGE 2005

First up it should be fun. Because it's only when you like doing something that you do it well. And so that today's juniors can ride circles around the seniors in a couple of years, we pack state-of-the-art technology into our smallest motorcycles as well. Constructed by racers for racers to have fun - and naturally, to win.

50 MINI ADVENTURE

The entry level bike for kids from 3 years and up. Controllable power is nice and easily delivered to the rear knobbly tyre thanks to the centrifugal clutch. With a weat height of 530 mm it is also safe for little ones to ride.

50 SENIOR ADVENTURE

The 50 Senior Adventure is the perfect match for small racers between the age of 6 and 8. This bike shines with its robuts air-cooled engine, increased travel and front disc brake. The seat height can be set to 650 or 675 mm.

SPORTMINICYCLES: TECHNICAL CHANGES 2005

The 2005 model range is shaped by the consistent further development of the hitherto successful models. These enhancements occur both on engine components and on the chassis. In the Sportminicycles the 85 SX is now offered as both a small- and large-wheel version.

For 2005 all MINI models get a new graphic design. In addition, the KTM lettering features silver shadowing.

50 MINI ADVENTURE

SHOCK ABSORBER

The rear shock has been shortened by 10 mm for a lower seat height. This makes things much easier for the smallest beginners from 3 years up and meets all race regulations.

CARBURETOR

A 65 main jet has been fitted as standard (hitherto 60). With a 70 main jet in the supplied kit, the carburetor set-up can be adjusted to all conditions.

85 SX

CLUTCH

On the 85 SX the piston diameter of the master cylinder has been reduced from 9.5 mm to 9.0 mm, which results in less effort for the rider and more precise application.

REAR BRAKE

New brake pads provide improved durability.

AIR FILTER

A new filter carrier with three fixing pins reduces the risk of fitting errors and means more safety for the engine.

MOTOCROSS SX MODELRANGE 2005

After such a long time on the MX scene, we know exactly what our riders need. When that starting gate falls, only one thing matters. We'll use any means necessary to get you to the head of the pack! Because no prisoners are taken in close combat. The only things that help you pass one oppo-nent after another are power and performance. And that's precisely why the (cylinder) heads smoke all night long in the KTM development depart-ment. The result: the new SX Generation. The finest crosser money can buy. Light, fast and - with the right PowerParts - easy to turn into your own individual dream bike. Are you "Ready to Race"? Then victory can be yours.

125 SX

Robust, light and the measure of all things in terms of power and performance: its power-to-weight ratio has been the decisive ar-gument in the 125 class for years. No bike whips through the curves better and yet remains easily controllable. With its re-vam-ped chassis and broadly usable rev range, the 125 SX leaves the competition's 4-strokes in the dust. Details like the adjustable CNC-machined triple clamp are normally available only on expensive factory bikes. But they're standard equipment in our SX models.

250 SX

The fine blade for all those who know what they're doing. Power to burn over a broadly usable powerband, perfectly applied due to the finest chassis technology. That means the 250 SX can stand up to every 450 four-stroke. And while the others are adjusting their val-ves again, you just fill ,er up and get a head start on your training.

525 SX RACING

It's somehow a good feeling not to have any real competition: with its outstanding performance, the 525 SX takes the competition apart at will in the open class. The perfect bike for the very courageous and for those who love power above all.

MOTOCROSS SX: TECHNICAL CHANGES 2005

As in previous years KTM again installs proven, high-quality components to its 2005 model range. So for all SX models, aluminium handlebars from Renthal, respectively Brembo brakes, Excel rims and hydraulic clutches are used. The 2005 model range is shaped by the consistent further development of the hitherto successful models. At the same time the experiences coming from the factory teams have been incorporated directly into the series. These enhancements occur both on engine components and on the chassis. There is a streamlining of the motocross model range (SX): the 200 SX has been removed from the program.

250 SX

CLUTCH

Softer springs mean less effort for the rider.

CYLINDER HEAD

The new shape of the combustion chamber increases compression, provides more power and improves the general engine characteristics.

GEAR LEVER

The new shape of the gear lever allows greater adjustability of the lever and more precise shifting.

CRANKSHAFT

The greater crankshaft diameter provides a more linear power progression, improved torque and optimal traction thanks to more momentum.

EXHAUST CONTROL

Using the two additional springs from the supplied kit, the engine characteristics can be adjusted to every rider and every track.

PISTON

Two piston rings instead of one ensure greater durability and less compression loss and therefore better performance.

CARBURETOR

The carburetor set-up has been adjusted for all the improvements.

525 SX RACING

IGNITION

The new CDI box with optimized ignition timing provides increased performance and at the same time more steering lock on account of the smaller dimensions.

CLUTCH

The modified pressure cap ensures better oil supply and consequently cooling of the clutch, greater durability and more precise application.

SX CHASSIS GENERAL

SPOILERS

The new, smaller design and the more stable construction provide greater manoeuvrability of the legs.

GRAPHIC

For 2005 all SX models get a new graphic design. In addition, the KTM lettering features silver shadowing.

FRAME

The chrome-moly frame has been further improved by the KTM technicians: new, oval lateral frame ties; a new, forged connecting bracket for the frame tubes and the shock upper mounting point; as well as new frame protectors have been used. The modifications guarantee an increased stiffness of the frame without any additional weight. The frame alterations reinforce the improved action of the suspension. The oval shape of the frame tubes additionally creates more space for the exhaust header pipe. Consequently KTM has at its disposal one of the lightest frame constructions on the market.

FORKS

The inner- and outer fork tubes have been totally redesigned to pro-vide a homogenous flex and therefore minimal friction. This contri-butes to the reduction of the number of bushing guides from three to two, which results in the forks working even better in all areas.

CHROME COATED PISTON ROD

The coating means less friction, reduced wear and increased durability.

DOUBLE-LIPPED SEALS and new dust strippers in combination with the new Motorex oil provide an improved seal and mean less mainte-nance. THE NEWLY TUNED front forks result in noticeably better responsive-ness and increased safety against bottoming.

TRIPLE CLAMPS

With the new, CNC machined triple clamps of reinforced aluminium, KTM again raises the bar for series motorcycles. Perfect fork clam-ping, with three screws per side at the bottom coupled with the gre-atest stability. And the highlight is the adjustable offset between 18 and 20 mm, so that the motorcycle's geometry as well as its handling can be individually set for any rider or riding surface. A childishly simple device with a great pay-off that is normally built into exorbi-tantly expensive factory machines.

SHOCK ABSORBER

THE MODIFIED PISTON ROD with larger inner diameter and three slots instead of four holes, as well as the rearrangement of the se-cond piston and the PDS needle improves functionality and increases safety against bottoming. A NEW SHOCK ABSORBER BODY and shorter compensating reser-voir benefit the ergonomics.

THE IMPROVED TUNING with progressive damping curve results in greater safety against bottoming-out, more comfort in the middle and better traction.

FRONT BRAKE

The reduced diameter of the master cylinder from 11 to 10 mm and the new geometry of the brake lever mean less force required at the lever and more precise application. The already high Brembo stan-dards have been improved even further.

REAR BRAKE

Increased heat resistance and therefore more constant braking per-formance (due to a broader temperature range) have been achieved thanks to new brake pads.

RENTHAL DUAL COMPOUND GRIPS

Thanks to the newest development from Renthal, a new material has been used which guarantees better damping quality while at the same time offering increased durability.

FENDER BRACE

The fitting of a fender brace on the SX models ensures increased stability of the front fender.

FUEL-OIL MIXTURE

For the 250 SX a mixture ratio of 60:1 is recommended due to the improved quality of the components. Less smoke and less pollution protect not only the environment, but also improve the reputation of 2-strokes.

OFFROAD MODELRANGE 2005

First things first: this sport has got nothing to do with logic. It requires a healthy dollop of masochism to get through the exertions of an Enduro World Championship round. While most armchair sportsmen tap their heads in bewilderment, like a woodpecker going after its lunch, KTM pilots plough their way through an enduro stage where experienced alpinists would have to get around on all fours. Why we do this to ourselves and our riders is easily explained: only under the toughest racing condi-tions does an enduro bike show its true worth. Technology that can with-stand the pace of world class riders like Juha Salminen or Ivan Cervantes makes for lots of fun and little hassle, both in national championships and away from competition. So it makes sense to go for a KTM.

125 EXC

The 125 EXC demonstrates its phenomenal power-to-weight ratio above all in the toughest terrain. Light as a trials bike, it simply floats over rock steps and other nasties. The refined chassis, together with a broad, usable rev band for a small 2-stroke, provide huge amounts of riding fun.

200 EXC

The best of both worlds. The weight of a 125 and pretty much the power of a 250. And even if it doesn't fit into the typical capacity classes, the 200 EXC is the ideal bike for anyone who is on the lookout for an extremely light implement with great torque and ample power reserves. The tougher the terrain the more its merits come into their own.

250 EXC

The 250 EXC brings world championship flair to your garage. Loads of power over a broad usable rev range easily put to use thanks to the finest suspension. So the 250 EXC can face up to any 450. The low maintenance required and above all the low weight are unbeatable advantages in favour of 2-stroke engineering.

300 EXC

The off-road workaholic in the KTM family: thanks to awesome torque right from the bottom, the 300 EXC keeps plugging on when others' engines have already boiled over. Its incomparably broad power band delivers any twists of the throttle straight to the rear wheel in a controllable manner.

400 EXC RACING

With its broad power band, great top-end performance and optimal traction, the 400 EXC Racing is the all-rounder in the KTM off-road program. The 400 EXC Racing is the most sought-after motorcycle on the KTM Adventure tours.

525 EXC RACING

With plenty of power in every situation, it dominates in the open class, whoever your opponents are. The distance to the person behind you is controlled simply by the right-hand wrist.

525 MXC DESERT RACING

Constructed for the demands of European Rallies. The 525 MXC combines long distance capabilities with the Enduro attributes of the EXC models. Differences to the 525 EXC Racing: 14 litre tank and radiator fan.

625 SXC

As a worthy successor to the legendary Super Competition, the 625 SXC shows its sporty talents on all terrains. The legendary LC 4 motor in its current development stage convinces with agile high revving and enormous torque. And the suspension comfortably deals with whatever comes under its wheels between the ice cream parlour and the cross country race.

OFFROAD: TECHNICAL CHANGES 2005

As in previous years KTM is again fits proven, high-quality components to its 2005 model range. So for all EXC models, aluminium handlebars from Renthal and Magura respectively Brembo brakes, Excel rims and hydraulic clutches are used. All EXC Racing models have an electric starter and X-ring chain.

The 2005 model range is shaped by the consistent further development of the hitherto successful models. At the same time the experiences coming from the factory teams have been incorporated directly into the series. These enhancements occur both on engine components and on the chassis.

EXC CHASSIS GENERAL

SPOILERS

The new, smaller design and the more stable construction provide greater manoeuvrability of the legs.

GRAPHIC

For 2005 all EXC models get a new graphic design. In addition, the KTM lettering features silver shadowing.

FRAME

The chrome-moly frame has been further improved by the KTM technicians: new, oval lateral frame ties; a new, forged connecting bracket for the frame tubes and the shock upper mounting point; as well as new frame protectors have been used. The modifications guarantee an increased stiffness of the frame without any additional weight. The frame alterations reinforce the improved action of the suspension. The oval shape of the frame tubes additionally creates more space for the exhaust header pipe. Consequently KTM has at its disposal one of the lightest frame constructions on the market.

FORKS

The inner- and outer fork tubes have been totally redesigned to pro-vide a homogenous flex and therefore minimal friction. This contri-butes to the reduction of the number of bushing guides from three to two. This results in the forks working even better in all areas.

CHROME COATED PISTON ROD

The coating means less friction, reduced wear and increased durability.

DOUBLE-LIPPED SEALS and new dust strippers in combination with the new Motorex oil provide an improved seal and mean less maintenance.

THE NEWLY TUNED front forks result in noticeably better respon-siveness and increased safety against bottoming.

450 EXC Racing

SHOCK ABSORBER

THE MODIFIED PISTON ROD with larger inner diameter and three slots instead of four holes, as well as the rearrangement of the se-cond piston and the PDS needle improve functionality and increase safety against bottoming.

A NEW SHOCK ABSORBER BODY and shorter compensating reservoir benefit the ergonomics.

THE IMPROVED TUNING with progressive damping curve results in greater safety against bottoming-out, more comfort in the middle and better traction.

LIGHT MASK

The new light mask on the EXC models with its innovative, pentago-nal plastic headlight provides more space for fixing the start number. The mask has a similar shape and the same brake hose guide as on the SXs.

RENTHAL DUAL COMPOUND GRIPS

Thanks to the newest development from Renthal, a new material has been used which guarantees better damping qualities while at the same time offering increased durability.

FUEL-OIL MIXTURE

For the 250 and 300 2-strokes a mixture ratio of 60:1 is recom-mended due to the improved quality of the components. Less smoke and less pollution protect not only the environment, but also im-prove the reputation of 2-strokes.

SWING ARM

The new design of the cast swing-arm, optimized for the main loading points, provides greater torsional stiffness and a high-quality appea-rance.

FRONT BRAKE

The reduced diameter of the master cylinder from 11 to 10 mm and the new geometry of the brake lever mean less force required at the lever and more precise application. The already high Brembo stan-dards have been improved even further.

REAR BRAKE

Increased heat resistance and therefore more constant braking per-formance (due to a broader temperature range) have been achieved thanks to new brake pads.

SPEEDOMETER

The new, digital speedo is smaller and the integrated buttons offer numerous extra functions (rally functions, lap times, more trip func-tions). The mounting bracket is made of plastic. The new speedome-ter saves space and gives a sporty appearance with optimal functiona-lity. A handlebar-mounted remote is available as an optional extra.

EXCEL RIMS

For 2005 all enduros get EXCEL rims (except 125/200 EXC). These are stronger, even safer and come with an orange Excel logo.

RACING BATTERY

A new, more powerful battery with new holder (for all Racing models) guarantees sure starting even under the most extreme conditions.

INDICATORS

Smaller indicators with flexible mountings replace the 2-part indica-tors. The new indicators are smaller and less breakable.

625 SXC

SIDE-STAND

The SXC is now fitted with a side-stand. A kill-switch ensures that the motorcycle cannot be operated with the stand down.

SPEEDOMETER

The new, digital speedo is smaller and the integrated buttons offer numerous extra functions (rally functions, lap times, more trip functions). The new speedometer saves space and gives a sporty appearance with optimal functionality. A handlebar-mounted remote is available as an optional extra.

FUEL TAP

A new fuel tap improves accessibility for a quick switch to reserve.

BRAKE DISC

Perforated brake disc in a lightweight, wave design, as on all the EXC models, improves braking performance.

525 SMR

Ready to Race in the S1 category, thanks to its super-agile handling and minimal weight. Lots of torque and plenty of power, which is passed to the asphalt via the specially tuned, 6-gear transmission and 165 slicks.

625 SMC

The sportier Supermoto. A smaller, 9-litre tank for slimmer ergonomics, a sportily narrow seat and a hot, Keihin flat - slide carb for spontaneous throttle response. It also has an electric starter.

660 SMC

The race horse among the street - licensed Supermotos. Maximum displacement, as athletically slim as its little sibling, but spartan in terms of weight. Now with even better performance, thanks to the new twin exhaust system borrowed from the Supermoto factory racers. The 660 SMC is "Ready to Race" for anything.

640 DUKE II

THE classic fun bike. Razor-sharp appearance, original design, light, aluminium cast wheels and even better performance, thanks to a new intake tract. The ultimate fun machine for humiliating the competitionon winding mountain roads and attracting attention at your favourite café.

625/660 SMC

REAR FENDER

New mud guards with integrated side panels, a new number-plate bracket, as well as a chic tail light, set new Supermoto standards.

SEAT

A new seat with sportier ergonomics and greater comfort. An easily reached latch enables quick access to the battery, air filter and tool compartment.

EXHAUST SYSTEM

New, twin silencers of light aluminium - almost like those the fac-tory racers are equipped with - plus a new header pipe routing provide a discernibly better power output as well as a sporty sound.

AIR FILTER BOX

A larger airbox for the 625 SMC (installed in the 660 SMC since 2003) and a new intake tract improve the gas-exchange cycle and thereby the engine's performance. A new air filter carrier with an integrated flame guard increases safety.

SUSPENSION

New, Supermoto-specific set-up of the 48 mm WP upside-down forks as well as of the WP monoshock (with reduced suspension tra-vel). Adjustability of the rebound damping and compression damping settings is standard on a KTM.

INDICATORS

New indicators with smaller orange glass and a longer operational life.

CHAIN

An X-ring endless chain (without a connecting link) eliminates the risk posed by the weakest link, i.e. the connecting link, which is always subject to the most wear.

SPEEDOMETER

The new digital speedo is smaller and features integrated operating buttons with numerous functions. The new speedometer saves space and offers a sportier appearance plus maximum functionality. A remote control on the handlebars is optional equipment.

GRAPHIC

There's a new graphic design for all Supermoto models in 2005. The KTM letters will be delineated with a silver shadow.

640 DUKE II

AIR FILTER BOX

A modified airbox with a new intake tract improve the gas-exchange cycle and thereby the engine's performance. A new air filter carrier with an integrated flame guard increases safety.

CARBURETOR

The jets conform to the modified intake conditions.

INDICATORS

New indicators with smaller orange glass and a longer operational life.

CHAIN

An X-ring endless chain (without a connecting link) eliminates the risk posed by the weakest link, i.e. the connecting link, which is always subject to the most wear.

BRAKES, REAR

New sintered brake pads further enhance the already high Brembo standards.