2022 KTM 450 SX-F What Would You Do?

People always ask, “what would you do to your own bike”? Most of the time that question gets answered at the track or through email, but I thought I would put it out there for the world to see through my site. The KTM 450 SX-F is one of my favorite bikes to ride and race. In stock form the 2022 KTM 450 SX-F has an easier to ride smooth roll-on power than other 450s in its class and that lets the rider get on the throttle sooner through corners. The stock suspension is decent but needs some better lean angle front end traction, more consistency in the front end and more hold up (high speed compression) on the shock. Not all of my builds need to be extravagant, so I thought why not build a machine strictly on what the bike “needs” to make it even more fun to ride/race. Below is a parts list that I have created on parts that I strictly wanted personally on my 2022 KTM 450 SX-F. Since the 22 KTM 450 SX-F is virtually unchanged from the 2021 version, there is no need to do a FIRST RIDE! 

Parts List: 

 FMF 4.1 

Titanium 4.1 Muffler System 

Fmfracing.com

WP/REP Pro Components

CV Fork Re-Valve (REP Spec)

Trax Shock (REP Spec) 

1mm Longer Shock Shaft

REP Knuckle/Rods

Repsuspension.com 

KTM

Factory Split Clamps

Ktm.com

Vortex ECU

Mapped By XPR Motorsports

XPRMotorsports.com

VP Racing

MR PRO 6 HT

Vpracing.com 

Pro Taper

EVO SX Race Bend

Protaper.com

 Dunlop

MX3S Front Tire (80/100-21) 13.5 PSI

MX33 Rear Tire (120/80-19 12.5 PSI

Dunlopmotorcyclestires.com

ZRT

Zero Resistance Aluminum Throttle 

Zrtthrottle.com

Twisted Development 

Exhaust Flange

Td-racing.com 

Although this parts list isn’t long, it is distinguished. The REP Pro Component suspension done up by Mark at REP has given me a lot more confidence in pushing this KTM 450 SX-F in longer motos under rougher conditions. REP has some unique parts that go inside the WP Pro Components which they make personally. The Pro Component (Cone Valve) fork now gives me more lean angle grip through corners and added comfort when the track gets rougher. I couldn’t say that with the stock AER fork, because it wasn’t consistent like this spring pro component REP fork. I always had a problem with my KTM’s riding rear end low, but with REP’s longer shock shaft accompanied by their linkage system, my new Garage Build has a balance that I have never had before. To go with my newfound balanced suspension package, I turned to Chad at XPR Motorsports to tune a programmable Vortex ECU for more excitement down low yet keep that stock linear character that I like so much. With the ECU installed along with Twisted Development’s exhaust flange the KTM now has a controlled snap out of corners that gives me the ability to hop over bumps better as well as gives the KTM a lighter feel. Did I mention it revved out like a 250? Yeah, that too! An FMF 4.1 exhaust rounds out the engine package and lightens up the KTM by over a pound, so there’s your bling. Sneaky mods that are a must have to me are a ZRT throttle that gives you a smoother overall feel and is much stronger than the plastic lock on system that KTM comes stock with. The ZRT is controlled via a bearing and that bearing gives you an unbelievable easier to use throttle even when your throttle cables get worn (which they will do around the 20-hour mark). These changes that I made make a huge difference and gets me excited to ride even when I am tired from a long week of testing. I don’t need all the bling with my bikes to get me excited, I just need a bike that performs out on the track and allows me to ride faster. I am more of a function over fashion type of rider with my machines and this KTM is now my type of vet racing 450. 

2020 Kawasaki KX250 Top 5 Mods

Kawasaki did a great job for 2020 on improving the KX250’s overall engine character as well as getting a much better suspension spec. Kawasaki made changes to the engine, went to a bigger throttle body, switched to KYB suspension, updated the brakes, changed the low front engine mounts, and shortened the headpipe by 30mm for 2020. We think they did a great job improving on the 2019 machine, but we have come across 5 fairly simple modifications to help the 2020 become even better. Here they are in no particular order: 

1. FMF Stainless Steel/Aluminum 4.1 Muffler System: The FMF Stainless 4.1 system will shed over two pounds off of your KX250, give you more mid range and top end pull, as well as keep the mid-to rpm response that the current stock exhaust comes with. The FMF system will not give you more bottom end pulling power, but going to the ECU map that we provide here will get you some increased low end rpm response with this FMF system. The FMF stainless/aluminum system is more cost effective and will not get as loose in the slip fit joints as a titanium 4.1 system. We tested a couple early versions of this muffler and are impressed with the final production FMF version.  

2. ECU Re-Mapping: We used Kawasaki’s Calibration Tool to tweak the fuel and ignition timing in order to try and get some more bottom end out of the 2020 KX250. The 2020 did lose a small amount of low end compared to the 2019, but we are in the market to get some added torque back for 2020. The map you see above will get you some of that torque back when exiting corners while maintaining the excellent mid-top end power that the 2020 comes with. Use the stock green coupler with this ECU setting…

3. Gearing: 13/50 gearing is just fine for the Intermediate to Pro level rider with either the green or white coupler. If you’re a heavier rider that is lazier in corners you can try a 13/51 gearing to help you get back into the meat of the power sooner. We suggest using the green coupler with our preferred ECU setting with the 13/51 gearing however. This will ensure that mid-top end pulling power doesn’t fall off too soon.

4. 110 Rear Tire: A few manufacturers still like to run a 100/90-19 rear tires because it’s lighter. However, the 110/90-19 rear tire offers more traction and has better comfort on square edge, hard pack areas of the track. The 110 doesn't weigh the 2020 KX250 down in deeper soil that much and in fact, I see no negative on the track to going up a size on the rear. The Kawasaki has plenty of mid-top end to carry the small amount of extra weight the 110 carries. You will get more lean angle bite coming out of corners as well as increased stability with the 110. The 110 will fit on your 1.85 rear rim so don’t worry about your standard current rim size with the 110 rear tire sizing. I am currently running a 110/90-19 Dunlop MX33 on the rear of the KX250 with good results in soft to intermediate terrain. 

5. Lower Handlebar Bend: The stock 7/8 971 Renthal bar bend feels too tall for the Kawasaki cockpit so I go with a 983 Renthal bend or purchase Ride Engineering’s bar mounts if you want a oversize 1-1/8 handlebar. The 983 7/8 bend has a slightly lower height and rise over the 971, which fits the KX250’s rider triangle better. If you’re going to a oversize bar/bar mount and are looking for a lower profile, go with a Pro Taper EVO/Fuzion SX Race bend. 

Bonus Tip: This is not a cost effective mod, but going to a full Hinson clutch kit will help the life of your KX250 clutch. Although the stock clutch feels good at the lever, the clutch does slip after some fairly normal abuse. Accelerating hard out of corners, when there is maximum grip, the stock clutch does slip under load. To prevent this you can get heavier springs, but that will not expand the life of your plates. Going to a full Hinson kit will prevent slipping as well as lengthen the life of your clutch.

If you have any questions please feel free to email me at kris@keeferinctesting.com

2020 KTM 450 SX-F World Vet Race Build Parts List

I raced the Keefer Inc. 2020 KTM 450 SX-F test bike on day two of the World Vet’s and I wanted to put together a parts list of everything that was on my bike. All of the parts on this list were either agreed upon or hand picked by myself because I knew they worked well. Through the testing process, as well as the countless laps I have done, I knew what worked at Glen Helen, but more importantly I knew what didn’t. I don’t race that often, but when I do, I train hard to make sure I am prepared. Doing that takes time and that time is precious to me. I am not about to line up for a race with parts on my bike that I don’t know make the bike (as a whole) work for the better. These parts on this machine were put in place because they made the KTM better at Glen Helen. There were only a few bling type pieces on this build because I wanted a bike with functionality and comfort, but also I had to make it look cool right? Below are the parts and the companies that were put in use on this build. 

Twisted Development Racing: www.td-racing.com 

Custom Ported/Decked Head

Custom Base Gasket

New Valve Seats 

Vortex Ignition With Custom Mapping ($950.00)

$1290.00

Why: At first when Jamie from Twisted Development asked me if I wanted a built race engine for the race, I immediately said “no, thanks”. He looked at me weird and asked “why not”? I told him I liked the stock engine character of the KTM and I did not want to have a bike that I couldn't hold onto for 20 minutes. He assured me that his head mod along with the Vortex ECU wouldn't change the character of the KTM’s engine, but only enhance it. I agreed and now that I have ridden/raced it, I am thankful that I did. The Twisted head mod utilizes the stock piston and cams, but Jamie custom CNC ports the head, decks it, and runs one of his custom base gaskets. This along with his ECU mapping (see below) gave me the most easy to ride KTM 450 SX-F engine that I have ridden to date. This engine gave me the holeshot in front of Mike Alessi in Moto one and was a pleasure to race. More legibility, increased recovery, with pulling power that killed the other machines up Mt. Saint Helens. It was just too bad the rider sucked it up on Sunday. I honestly can’t wait to ride this sucker even more in the coming weeks!  

FMF Racing: www.fmfracing.com 

FMF 4.1 RCT Muffler System 

$1049.00

Why: Simply put, the FMF system gives me more excitement down low with a broader mid-top end pull. You can check out the review right here on keeferinctesting.com

WP Suspension: www.wp-suspension.com 

XACT Pro 7548 Fork

XACT Pro 8950 Shock

Factory Triple Clamp 

Why: WP’s XACT Pro Components are usually found on all of my KTM’s and Husqvarna’s I race with. Why? I get more consistency and performance out of the XACT Pro Components than that of the stock AER fork/stock WP shock. I tested some stock settings back to back with the WP Pro Components the week leading up to the World Vet’s and came away with this opinion: The first thing I noticed when I went out on the track with the XACT fork was that the KTM turns slightly slower than the AER fork on initial lean (into corners) which is exactly what I wanted at GH. You can actually feel the extra weight right away in the front end compared to the stock AER fork, but it wasn't a bad feeling, I was just surprised I could feel it this much when entering corners. Usually I run the fork flush at GH, but with the slower turn in feel I went with a 5mm height. Along with the extra weight feeling however I gained more front end traction through every corner (especially flat corners). The XACT fork leaves you with a more front end tire contact patch sensation and you can lean over more in ruts without getting the high front end, vague feeling like you can with the AER fork. With the AER fork I get some pushing in the front end through the middle to end of the corner at GH, which made me roll off the throttle to try and compensate. With the XACT fork I can lean in the corner and the fork stays planted, which let my front end settle and bite. The WP XACT fork also felt less active on braking bumps. I am able to jump in and out of bigger bumps that Glen Helen offered without having the fork rebound too quick and be too active. If I wanted to pound through the bumps, the fork had a better damping control feeling through the middle to end part of the stroke. The most notable change was to my wrists when over jumping or flat landing with the XACT fork. I started to over jump a single out into some braking bumps in one area of the track and the XACT fork left me with a feeling that I could do this every lap. 

The XACT shock holds up better than the stock shock for me on high speed compression and you are able to get more aggressive around the track. I can hit the faces of jumps harder and the KTM did not give me an empty/low feeling sensation that the stock shock sometimes gave me at GH. In order to combat that feeling with the stock shock I would have to crank up the high speed compression so much that I would lose the comfort coming out of corners (and rear wheel traction). THAT’S NOT FUN AT GH! The Trax shock provides you with more high-speed damping and you still get a decent amount of acceleration comfort on choppy corner exits. I also noticed a little more connectivity to the the rear wheel (when hard on the gas) on flat corners with the Trax shock compared to the stock shock I tested the week before the event. The Trax shock is firmer so there is less wallow in the rear end when accelerating, so the rear of the KTM 450 SX-F tracks straighter and doesn't upset the chassis as much. “Balanced” is a great word to describe both ends of the KTM that I raced, but I did notice the harder I pushed the more it rewarded me. If I tried to ride smoother/slower the action of the shock wasn't quite as comfortable as the stock shock.  

Hinson: www.hinsonracing.com 

Billetproof Inner Hub And Pressure Plate 

$519.99

Why: The Hinson billetproof inner hub and pressure plate gives me longer life between clutch plate changes as well as slippage under heavy load/abuse. This mod was incorporated into the build more for durability (for after the event, then the event itself).

Pro Taper: www.protaper.com 

SX Race Fuzion Handlebars 

$129.99 

Why: I use the Pro Taper Fuzion bars because I like a crossbar on a KTM and they still give me enough flex to where the bike doesn't feel rigid. Some other crossbar handlebars out there make the bike feel rigid and I hate that feeling. 

Vortex Ignitions: www.vortexcdi.com or www.td-racing.com 

ECU 

$950.00 (with 10 Twisted Development maps installed)

Why: This has been a mod that I have been preaching for years. The Vortex ignition, along with Jamie’s maps, gives the KTM a stronger pulling power out of corners, an increased mid range hit, as well as a top end over-rev that you have to feel to believe. I still can’t get over how good this KTM is up the hills of GH. The thing pulls third gear forever! WIth this Vortex ignition and a FMF muffler, the KTM becomes a whole different motorcycle!  

VP Racing: www.vpracingfuels.com 

MR Pro 6 HT

Why: Jamie mapped the Vortex ignition for Pro 6 fuel to get the most horsepower possible out of my KTM 450 SX-F for the race. I am now back on pump fuel because I am just a local practice guy now.  

Throttle Syndicate: www.throttlesyndicate.com 

Graphics and Seat Cover 

$199.99 

Why: Throttle Syndicate are good dudes and make some cool stuff. I love how they tied in the orange blue and white to make the whole bike pop. I am usually not a graphic/pre-print guy, but when you're racing you might as well look the part right? Throttle Syndicate did this bike up right! Where is the fire emoji at?!

Works Connection: www.worksconnection.com 

Axle Blocks $59.95

Custom Hydraulic Clutch/Brake Reservoir Cover Caps $37.45 each

Pro Launch Start Device $119.95 

Oil Filler Cap $24.95

Why: Works Connection is one of the best companies I have ever come across. The people, the products, as well as the customer service you get is second to none. When racing, the Pro Launch Start Device is a must and easy to use. It’s so easy to use that my wife Heather can even lock down my front end, so you know it’s easy! The custom caps that WC are doing with your racing number is very cool and gives you that factory look. The Elite Axle Blocks is a must have if you’re a Husqvarna or KTM owner because it removes the fixed left side chain block and allows the rear of your bike to move freely under acceleration. It’s a simple mod that helps the comfort of your chassis.

Dunlop: www.dunlopmotorcycletires.com 

MX53 Front Tire

MX33 Rear Tire 

Why: Glen Helen never stays soft and loamy. It turns into hard pack, square edge by 11:00 AM, so I needed a front tire that gripped well on lean angle, under hard pack conditions. After the MX53 tire launch I knew that the MX53 front tire would be my weapon of choice in those conditions at Glen Helen. Although I do like a MX53 rear tire, I needed a softer tire to get out of the gate and down the deep start straight of GH, so the MX33 did it’s job and got me two excellent starts on the weekend. If you have a track that is soft in the morning and gets somewhat hard pack in the afternoon the MX53 tires work very good. 

Acerbis: www.acerbisusa.com 

Complete Plastic kit $159.95

Frame Guards $49.95 

Why: Acerbis makes great plastic that fits well, has the OEM original colors, and my OEM plastic was hammered. The frame guards also provide me with extra grip when squeezing the bike coming down those bumpy ass Glen Helen hills. 

FirePower: www.firepowerparts.com 

Battery

O-Ring Chain 

Why: I have had one battery go dead on the KTM 450 SX-F this year, so I decided to put a reliable/lighter lithium ion battery in the orange machine and FirePower has been my go to for more than just my KTM. The stock KTM chains aren't bad, but mine was due to re-placed and since FirePower has durable O-Ring chains, I decided to put one on for this race and beyond. After initial the stretch, I usually only have to adjust the chain a couple times, so less maintenance is good maintenance in my eyes.  

Looks so good that you just have to take one last look!