YZ 300X Project Build: Can We Get It On Par With The KTM 300?
Hey guys, Jeff here from Slavens Racing. If you know us, you know we love our KTM 300s. But this time, I wanted to see just how close we could get this 2016 YZ 250X to my 2024 KTM 300 XC-W, also known as “The Orange Benchmark.” It’s no secret the KTM sets the bar — but the BluCru has been barking up a storm, and it’s time to see if their yips and yaps have any merit.
Goals
Our initial goal was to take a current generation YZ 250X, add basic parts to hit the big deficits, and see if it ended up in the same ballpark (or even county) as a current KTM 300. However, our vendors caught wind of this project it evolved (read: spiraled) into the blue depths of which no KTM aficionado dares to go.
Engine & Performance Mods
The YZ 250X can be a pipe-y handful out of the box, considering it is a motocross bike at heart. To close the gap to a KTM 300, we started with a Cylinder Works Big Bore Kit, pushing displacement and bumping torque across the board. I had to dig back into my memory from working with AmPro Yamaha in the two stroke days to remember how to get this thing to rev. We came across a few concerns in the Cylinder Works instruction manual that may guide you down the wrong road. If you order that kit for your YZ, be sure to give us a call and we can help you out.
To help get us closer to the TBI response, we added the Lectron Billetron Pro-Series 38 carburetor and Moto Tassinari V-Force 4X Reeds. This was a huge step in the right direction, and who wants to change jets anyway? What is this, 2006?
We added a Vortex X10 CDI that allowed us to tune ignition timing, and a Fisch Moto E-Start finally brought modern convenience to the blue bike. There has been a high profile case of user error that might make people looking into the Fisch kit nervous, but rest assured, we have put it through its paces and had nothing but excellent results.
Cooling is sorted with the Samco Radiator Hose Kit, while exhaust is a combination of FMF Fatty and FMF Turbinecore 2.1 for a consistent 2T punch at a moderate tone. We’re looking for broad, strong, smooth power with this build, and this combination matches what we were looking for.
We decided to run the all new Rekluse Apex Clutch. This is a manual clutch system that we have been really impressed with. The engagement and feel is a big step up from the stocker. Internally, it looks like it took a few cues from the KTM OEM system, which could be what is bringing about that familiar feel.
Suspension and Comfort
The stock YZ suspension is “ok” in some areas, like fast and flowy terrain, and just plain bad technical, rocky terrain. Since this build was already off the rails, we skipped a revalve and went with Slavens Mule MX-Tech Raven Cartridges up front, and out back, the MX-Tech National Shock. These upgrades transform bump compliance, traction, and confidence—finally letting the Yamaha carve and claw with the best of them.
For ergos, the XC Gear Mako 360 takes the edge off harsh hits. Warp 9 Handlebars and Renthal Grips give you the better cockpit feel, while a Polisport Seat & Restyle Kit and Seat Concepts Cover & Foam add comfort and modern looks.
Wheels, Tires, Brakes & Drive
We wanted to do something different with the wheels, and HAD to do something different about the brakes. No matter what we tried, we could not get the initial mushy feeling out of the first part of the brake engagement. After phoning a friend at Yamaha, we needed to look into aftermarket options, enter the Wheel Worx Oversized Rotors. This kit sharpened up our brake feel and stopped the bike on a dime.
We went with Warp 9 Elite Wheel Assemblies front and rear for strength, reliability, and style. and we kept it protected with a BPD Front Disc Guard, BPD Rear Disc Guard, and BPD Caliper Guard.
Between our Molecule and BPD parts, you might be picking up on a recurring theme. These are two solid brands who build excellent products, and go above and beyond for the customer.
Drive upgrades include Dirt Tricks Front Sprocket, Dirt Tricks Rear Sprocket, and Acerbis Chain Guide and Slide Kit.
To keep it hooked up, we chose the IRC JX8 and IRC VX40 tires with Tubliss and Nitromousse 5150 half mousses. We have great traction, and run low pressure, and even keep rolling if we get a flat.
Protection & Reliability
This build gets the works: Molecule Skid Plate, Molecule Handguards, E Line Carbon Fiber Pipe Guard, BPD Radiator Guards, BPD Swingarm Guard, BPD Case Saver, Acerbis Frame Guards, and more—all designed to keep the YZ 300X running strong and looking sharp, no matter how hard you push it (or from how high you drop it).
YZ 300X vs KTM 300: The Final Verdict
From what started as a basic build, and spiraled into a “whole enchilada” build, the bike has been updated and refined in as many ways possible.
So, did we get the YZ 300X up to par with a brand new KTM 300 XC-W? The answer is “No.” That shouldn’t be surprising, and it wasn’t for lack of trying. It’s been nearly 20 years since the blue bike has seen a significant redesign, and overcoming the fundamental engineering of the engine and chassis is a hurdle the aftermarket has yet to solve.
However, that’s not to say it’s a bad bike – to get it in the same ballpark as the Orange Benchmark is impressive. To put it into perspective, imagine we tried doing the same thing with a 2006 KTM 300 EXC…
