ENGINE: KTM North America gets these engines
straight from the Austrian factory completely assembled.
The only time they come apart is for maintenance or if they
have major issues. The engine is tagged as the 450 Rally
motor designed for KTM’s Rally race team. The motor is
based off of the 2012 450 SXF twin-cam, carbureted bike.
It’s fit with a Pankl rod and piston, has stock compression,
factory cam timing and with some factory porting; grinding
and flow mods produce what they deem as “optimal mid-to top-end power.” Internally, the clutch is factory stock,
though there are additional oiling ports to help longevity.
And, it uses a special Duval transmission, stock Del West
valves, and older-model SX wide radiators that are modified to accept stock hoses so that they can use stock radiators if something were to happen during the race. Engine
Ice coolant, Motorex 10W- 60 full-synthetic oil and VP T4
fuel handle the fluids.
ELECTRONICS: The ignition cover on this motor is
specifically built to house the stator and flywheel out of a
350EXC machine. This has to be done so that they can
run a headlight and taillight. This motor was never
intended to run any kind of lights, so the stock compo-
nents were made to run the bike, and that’s it. With the
different stator and flywheel, Anthony had to fit up a big-
ger regulator. For this new weld, tabs are welded onto
the frame in a new location. The wiring harness is
altered, as Anthony extended some wires, changed a
couple of connectors and made a harness for the lights.
The first time he did this, it took an entire day to get it
right. The CDI is off of the rally bike. The mapping in it is
made for durability and controllable power. The CDI box
they used for the San Felipe 250 was more like a stock
bike, but the CDI for the 500 had the rev limiter lowered
about 1000 rpm for more durability. Surprisingly, during
testing, the San Felipe CDI box topped out at 118 mph,
and the 500 CDI topped out at 108 mph. The San Felipe
CDI rated way higher on the fun meter, pulling fast and
hard through the power curve. It worked great in the
EXHAUST: The exhaust is special made by FMF
specifically for factory Baja motors. The header is made
for better all around power and superior top end power
for the long valleys and dry lakebeds across the desert.
The mid pipe is also special made for greater power.
The muffler uses a special heavy packing muffler that
doesn’t blow out from sustained drama. Both the header
and mid pipe are stronger than stock FMF systems to
handle long-term abuse.
The Bonanza/FMF/Factory KTM is based around the carbureted 450SX engine. This is the same motor that the Rally
team uses, so USA purchases the engines built from the factory and bolts them in. Every other part on the machine can
be purchased via the aftermarket, or KTM Hard Parts.
INSIDE THE KTM FACTORY BAJA MACHINE