2020 vs 2025 KTM 300 XC-W Technical Comparison
Engine Specifications
| Specification | 2020 300 XC-W TPI | 2025 300 XC-W |
|---|---|---|
| Displacement | 293.15 cc | 293.15 cc |
| Bore/Stroke | 72 mm / 72 mm | 72 mm / 72 mm |
| Compression Ratio | 12.7:1 | Not specified |
| Control Port | 1 exhaust control port | 1 exhaust control port (electronically controlled) |
| Ignition System | Contactless controlled fully electronic ignition | Contactless controlled fully electronic ignition |
| Spark Plug | NGK BR 7 ES | NGK BR 7 ES |
| Spark Plug Gap | 0.6 mm (0.024 in) | 0.6 mm |
| Idle Speed | 1,400-1,500 rpm | 1,400-1,500 rpm |
| Primary Drive Ratio | 26:73 | 26:72 |
| Engine Design | Single cylinder, 2-stroke, water-cooled, reed intake | Single cylinder, 2-stroke, liquid-cooled, diaphragm intake |
| Starter | Electric starter | Electric starter |
| Lubrication System | Electronic oil pump with adjustable oil feed | Electronic oil pump |
Transmission & Gearing
Gear Ratio Calculation: Higher numbers = lower gears (more torque multiplication, slower wheel speed). Lower numbers = higher gears (less torque multiplication, faster wheel speed).
Overall Ratio Formula: Gear ratio × primary ratio × final drive ratio = total reduction ratio.
Gear Ratios
| Gear | 2020 Ratio | 2025 Ratio | Ratio Change |
|---|---|---|---|
| Primary Drive | 26:73 (2.808) | 26:72 (2.769) | 1.4% taller |
| 1st Gear | 14:32 (2.286) | 13:33 (2.538) | 11% shorter |
| 2nd Gear | 16:26 (1.625) | 16:30 (1.875) | 15.4% shorter |
| 3rd Gear | 20:25 (1.250) | 18:26 (1.444) | 15.5% shorter |
| 4th Gear | 22:23 (1.045) | 22:26 (1.182) | 13.1% shorter |
| 5th Gear | 25:22 (0.880) | 23:23 (1.000) | 13.6% shorter |
| 6th Gear | 26:20 (0.769) | 26:22 (0.846) | 10% shorter |
| Final Drive | 13:50 (3.846) | 13:45 (3.462) | 10% taller |
| Chain Type | 520 X-ring | 520 X-ring | No change |
Overall Gearing Analysis
| Gear | 2020 Overall Ratio (13:50 final) | 2025 Overall Ratio (13:45 final) | 2025 vs 2020 Gearing |
|---|---|---|---|
| 1st | 24.68 | 24.33 | Higher (taller) |
| 2nd | 17.55 | 17.97 | Lower (shorter) |
| 3rd | 13.50 | 13.85 | Lower (shorter) |
| 4th | 11.29 | 11.33 | Lower (shorter) |
| 5th | 9.50 | 9.59 | Lower (shorter) |
| 6th | 8.31 | 8.11 | Higher (taller) |
Gearing Analysis:
2025 transmission changes: Taller final drive (13:45 vs 13:50) compensated by shorter internal ratios in gears 2-5.
- 1st gear: 1.4% taller overall - reduces wheel spin in technical sections
- 2nd-5th gears: 0.4-2.6% shorter overall - maintains engine rpm between shifts
- 6th gear: 2.4% taller overall - lower rpm at cruising speed
- Result: Tighter gear spacing reduces rpm drop between shifts
Suspension Specifications
| Component | 2020 300 XC-W TPI | 2025 300 XC-W |
|---|---|---|
| Front Fork | WP XPLOR 5348, 48mm, 292mm travel | WP XPLOR CC, 48mm, 300mm travel |
| Fork Damping Settings | Compression: 15 clicks, Rebound: 15 clicks | Compression: 15 clicks, Rebound: 17 clicks |
| Triple Clamp Offset | 22 mm (0.87 in) | 22 mm |
| Rear Shock | WP XPLOR 5746 PDS, 310mm travel | WP PDS, 310mm travel |
| Shock Damping Settings | LSC: 15 clicks, HSC: 2 turns, Rebound: 15 clicks | LSC: 15 clicks, HSC: 2 turns, Rebound: 15 clicks |
| Suspension Sag | Static: 37mm, Rider: 110mm | Static: 38mm, Rider: 110mm |
| Adjustment Features | Compression/rebound damping adjustable | Tool-free compression/rebound adjustment |
Fuel System Details
| Feature | 2020 300 XC-W TPI | 2025 300 XC-W TBI |
|---|---|---|
| Fuel Injection Type | Transfer Port Injection (TPI) | Throttle Body Injection (TBI) |
| Throttle Body | Dell’Orto 39mm | Keihin 39mm |
| Fuel Injectors | 2 injectors in transfer ports | 1 injector in throttle body |
| ECU Parameters | Basic ECU monitoring | 6 parameter analysis (throttle, speed, temp, pressure, etc.) |
| Fuel Tank Capacity | 9.0 liters (2.4 US gal) | 9.0 liters |
| Fuel Grade | Super unleaded (ROZ 95/RON 95/PON 91) | Super unleaded (ROZ 95) |
| Fuel Pump | Electronic fuel pump in tank | Electronic fuel pump |
| Map Selection | 2 maps via handlebar switch | Quickshift+ customizable mapping |
Dimensions & Capacities
| Specification | 2020 300 XC-W TPI | 2025 300 XC-W |
|---|---|---|
| Wheelbase | 1,482 ± 10 mm (58.35 ± 0.39 in) | 1,488 ± 10 mm |
| Ground Clearance | 370 mm (14.57 in) | 347 mm |
| Seat Height | 960 mm (37.8 in) | 963 mm |
| Weight (without fuel) | 103 kg (227 lb) | 104.6 kg |
| Gear Oil Capacity | 0.80 L (0.85 qt) | 0.80 L |
| 2-Stroke Oil Tank | 0.6 L (0.6 qt) | 0.8 L |
| Coolant Capacity | 1.2 L (1.3 qt) | 1.2 L |
| Steering Head Angle | 63.5° | 63.5° |
| Front Tire | 90/90-21 54M TT Dunlop GEOMAX AT 81 F | 80/100-21 M/C 51M M+S TT Dunlop GEOMAX MX33F |
| Rear Tire | 110/100-18 64M TT Dunlop GEOMAX AT 81 | 140/80-18 M/C 64M M+S TT Dunlop GEOMAX AT81 |
| Tire Pressure | Front: 1.0 bar (15 psi) / Rear: 1.0 bar (15 psi) | Front: 1.0 bar / Rear: 1.0 bar |
| Battery | HJTZ5S-FP-C Li-ion, 12V, 2.0 Ah | HJTZ5S-FP-C Li-ion, 12V, 2.0 Ah |
| Alternator | 12V, 196W | Not specified |
| Headlight | HS1 / BX43t socket, 12V, 35/35W | LED |
| Brake/Tail Light | LED | LED |
| Main Fuse | 20A | 20A |
Feature Comparison
| Feature | 2020 300 XC-W TPI | 2025 300 XC-W |
|---|---|---|
| Fuel System | TPI - Dell’Orto 39mm throttle body | TBI - Keihin 39mm throttle body with ECU |
| MSRP | $10,099 | $11,449 |
| Engine Weight | Not specified | 52.6 lbs |
| Fork | WP XPLOR 48mm open cartridge | WP XPLOR 48mm with updated settings |
| Shock | WP XPLOR PDS | WP XPLOR PDS with improved pressure balance |
| Power Valve | Mechanical control | Electronic control |
| Oil Injection | Electronic pump | Improved electronic pump |
| Airbox | Standard design | Tool-free access with splash protector |
| Exhaust | Standard expansion chamber | Increased ground clearance design |
| Mapping | 2 maps (standard/soft) | Quickshift+ with customizable maps |
| Clutch | Diaphragm spring (DDS) | DDS with Brembo hydraulics |
| Transmission | Pankl 6-speed | 6-speed wide-ratio |
| Steering Head | Standard connection | Forged connection |
| Subframe | Aluminum | 2-part polyamide/aluminum |
| Frame | Motor positioned 1° downward | Black powder coat, repositioned rotating masses |
| Brakes | Brembo (260mm front/220mm rear) | Brembo (260mm front/220mm rear) |
| Handlebars | Neken aluminum | ProTaper aluminum |
| Electronics | Basic ECU | Offroad Control Unit (OCU) + KTMConnect |
| Wheels | Standard alloy | GIANT alloy with CNC hubs |
Critical Tightening Torques
| Component | 2020 300 XC-W TPI | 2025 300 XC-W |
|---|---|---|
| Cylinder Head Nuts | 25 Nm (sequence: crosswise) | Not specified |
| Spark Plug | 27 Nm | Not specified |
| Engine Mounting Bolts | Upper: 45 Nm, Lower front: 45 Nm, Lower rear: 60 Nm | Not specified |
| Triple Clamp | Upper: 17 Nm, Lower: 12 Nm | Not specified |
| Rear Axle Nut | 80 Nm | Not specified |
| Front Axle Clamp | 15 Nm | Not specified |
2020 TPI Technical Points
- Counter-balanced engine reduces vibration
- Motor angle improves front wheel traction
- Open cartridge fork has reduced breakout force
- Pankl transmission proven in extreme conditions
2025 TBI Technical Updates
- TBI analyzes 6 parameters for precise fueling
- Frame complaints led to 2025 revision
- Tool-free suspension adjustments
- Electronic power valve for altitude compensation
- Header pipe raised for rock clearance
- Softer power than TPI per rider feedback
- OCU replaces fuses with electronic switching
Detailed Technical Analysis
Engine Specifications
Both engines: 293.15cc, 72mm bore × 72mm stroke. 2020 uses reed valve intake, 2025 uses diaphragm controlled intake. Primary drive ratio changed from 26:73 (2020) to 26:72 (2025). 2020 TPI injects fuel directly into transfer ports via two injectors. 2025 TBI uses single injector in 39mm Keihin throttle body. Electronic power valve on 2025 adjusts exhaust port timing based on atmospheric pressure sensor input. Both engines use same NGK BR7ES plug, 0.6mm gap, 1,400-1,500 rpm idle.
Transmission Specifications
6-speed claw-shift transmissions on both. 2025 revised all gear ratios: 1st changed from 14:32 to 13:33, 2nd from 16:26 to 16:30, 3rd from 20:25 to 18:26, 4th from 22:23 to 22:26, 5th from 25:22 to 23:23, 6th from 26:20 to 26:22. Final drive changed from 13:50 to 13:45 (10% taller). Both use wet multi-disc DDS clutches with hydraulic actuation. 2025 specifies Brembo master cylinder. Gear oil capacity: 0.80L for both models. 520 X-ring chain standard.
Suspension Specifications
Fork: 2020 WP XPLOR 5348 (292mm travel), 2025 WP XPLOR CC (300mm travel). Both 48mm, 22mm offset. Fork settings: 2020 = 15 compression/15 rebound, 2025 = 15 compression/17 rebound. Rear: Both use WP PDS system, 310mm travel. Shock settings identical: 15 clicks LSC, 2 turns HSC, 15 clicks rebound. Sag specifications: 2020 = 37mm static/110mm rider, 2025 = 38mm static/110mm rider. No linkage on either model (PDS = Progressive Damping System with direct shock mount).
Fuel System Specifications
2020 TPI: Dell’Orto 39mm throttle body, two injectors in transfer ports, basic ECU, 2 fixed maps. 2025 TBI: Keihin 39mm throttle body, single injector, OCU (Offroad Control Unit) monitors throttle position, wheel speed, coolant temp, atmospheric pressure, engine speed, exhaust temp. Fuel capacity: 9.0L both models. Fuel requirement: ROZ 95/RON 95/PON 91. 2-stroke oil tank: 2020 = 0.6L, 2025 = 0.8L. Electronic oil pumps on both.
Frame & Chassis Specifications
Both use central tube chromoly steel frames. Steering head angle: 63.5° both models. Wheelbase: 2020 = 1,482±10mm, 2025 = 1,488±10mm. Ground clearance: 2020 = 370mm, 2025 = 347mm. 2025 adds forged steering head connection and black powder coating. Subframe: 2020 = aluminum, 2025 = 2-part polyamide/aluminum construction. Triple clamp offset: 22mm both models. Brakes: Brembo 260mm front/220mm rear discs on both.
Dimensions & Weight
Dry weight: 2020 = 103kg, 2025 = 104.6kg (+1.6kg). Seat height: 2020 = 960mm, 2025 = 963mm (+3mm). Ground clearance: 2020 = 370mm, 2025 = 347mm (-23mm). Wheelbase: 2020 = 1,482mm, 2025 = 1,488mm (+6mm). Fuel tank: 9.0L both models. Coolant capacity: 1.2L both. Gear oil: 0.80L both. 2-stroke oil: 2020 = 0.6L, 2025 = 0.8L (+0.2L).
Electrical System
Alternator: 2020 = 196W, 2025 = not specified. Headlight: 2020 = HS1 halogen 35/35W, 2025 = LED. Tail light: LED both models. Battery: HJTZ5S-FP-C lithium-ion 12V 2.0Ah both models. Main fuse: 20A both. ECU: 2020 = basic unit with 2 maps, 2025 = OCU (Offroad Control Unit) with electronic fuse replacement, customizable mapping, diagnostic capabilities. Power valve: 2020 = mechanical, 2025 = electronic with altitude compensation.
Tire Specifications
2020: Front 90/90-21 54M TT Dunlop GEOMAX AT81F, Rear 110/100-18 64M TT Dunlop GEOMAX AT81. 2025: Front 80/100-21 51M M+S TT Dunlop GEOMAX MX33F, Rear 140/80-18 64M M+S TT Dunlop GEOMAX AT81. Pressure: 1.0 bar (15 psi) front/rear both models. 2025 rear tire 30mm wider (140 vs 110). Front tire narrower on 2025 (80 vs 90). M+S rating on 2025 tires only.
Service Requirements
Spark plug: NGK BR7ES, 0.6mm gap both models. Idle speed: 1,400-1,500 rpm both. Gear oil: 0.80L both. Coolant: 1.2L both. 2-stroke oil tank: 2020 = 0.6L, 2025 = 0.8L. Torque specs available for 2020 only: cylinder head 25Nm crosswise pattern, spark plug 27Nm, engine mounts 45/45/60Nm (upper/lower front/lower rear), triple clamp 17/12Nm (upper/lower), rear axle 80Nm, front axle clamp 15Nm.
Hard Enduro Specific Considerations
2020 Technical Points: TPI system with two transfer port injectors. 370mm ground clearance. 196W alternator output. Reed valve intake. Halogen headlight. Mechanical power valve. 90mm front tire width. 292mm fork travel.
2025 Technical Points: TBI system with single throttle body injector. Electronic power valve with altitude compensation. OCU replaces traditional fuses. LED lighting throughout. Tool-free suspension adjusters. 300mm fork travel. 140mm rear tire width. 0.8L oil tank.
Technical Summary: Primary differences: fuel injection location (transfer ports vs throttle body), power valve control (mechanical vs electronic), ground clearance (370mm vs 347mm), fork travel (292mm vs 300mm), electrical system complexity. Both use same displacement, bore/stroke, basic architecture. 2025 adds altitude compensation via atmospheric pressure sensor. Gearing changes result in tighter ratio spacing. Weight difference 1.6kg. Price difference $1,350.