Every engine that comes into KTM’s Factory Services
department gets dyno tested and broken in.
Although the exotic works parts are expensive, most of what
you pay for at Factory Services is the loving care they put in.
YOU CAN’T STOP BY THE SHOP AND TALK TO THE MECHANICS (WE DID, BUT YOU CAN’T). YOU CAN’T CALL THEM ON THE PHONE (THEY ARE BUSY). YOU CAN’T BROWSE THE FACTORY SERVICES WEBSITE (BECAUSE THERE ISN’T ONE).
Step one: You can’t stop by the shop and talk to the mechanics (we did, but you can’t). You can’t call them on the phone (they are busy). You can’t go to the KTM website and browse the Factory Services page (because there isn’t one). Nope! The only way is by sending an e-mail to facto- firstname.lastname@example.org. Once they get your e-mail, they will respond with all you need to know. Step two: Factory Services doesn’t work on complete bikes. They only want your engine (and nothing else). In order for Factory Services to work on your engine, you have to send it to them. Plus, they will only accept 2013 KTM 250SXF, 350SXF or 450SXF engines. Did we mention that they prefer that your engine have low hours? They will accept engines with more than a few hours on them, but they will replace any parts they find suspect. MXA gave Factory Services a brand-new KTM 350SXF engine, which we got from KTM. This was a plus, because we didn’t have to ship it to them, which was another plus, because shipping engines is a hassle. Step three: Once Factory Services gets your engine, they tear it down…all the way down. They split the cases, pull the crank apart, inspect the oil pump and replace the stock parts with fancy works parts. Although the 350SXF gets the same attention as the 250SXF and 450SXF, it doesn’t get the lightweight, polished Pankl rod; DLC crank pin; or special, close-ratio transmission from Aubert & Duvall. Nor does it have the center cases machined to allow the use of a center-case gasket like the 450SXF. Instead, the 350SXF gets blueprinting and a close inspection of each part. It is then reassembled with the crank balanced and trued. Step four: Next, Factory Services turns its attention to the cylinder and piston. Your stock piston is replaced with a special, 30-gram-lighter, anti-friction-coated Pankl piston. Once the cylinder and piston are in place, the deck height is set to perfection. There are three different thicknesses of base gaskets available to ensure the proper height (and if that fails, they will machine the cylinder). Before moving to the cylinder head, Factory Services laps the top of the cylinder to ensure a true and flat surface for the gasket. EVERY ENGINE THAT COMES INTO FACTORY SERVICES GETS A KTM SXS CYLINDER HEAD THAT HAS BEEN PORTED AND POLISHED AT THE AUSTRIAN FACTORY. KTM WILL SEND YOUR OLD HEAD BACK TO YOU—THEY DON’T NEED IT.
Step five: Every engine that comes into Factory Services gets a KTM SXS cylinder head that has been ported and polished at the Austrian factory. KTM will send your old head back to you—they don’t need it. They lap the bottom of the cylinder head and then mate it to the cylinder. At this point, they assemble the drivetrain using lightweight MWR titanium valves and stiffer valve springs. During assembly, Factory Services runs a