– KTM used the recent break to carry out a comprehensive overhaul of the MotoGP engines that had recently been plagued by defects. A total of seven units were opened at the manufacturer’s engine center in Munderfing.
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The components identified as possible causes of the failures were replaced. Afterwards, the engines were resealed and can now be used again in the regular engine pool.
The work began last Monday at the KTM engine center in Munderfing, just a few kilometers from the company headquarters in Mattighofen. The measure was carried out under the utmost secrecy. Previously, the other MotoGP manufacturers had granted KTM permission to open the engines that were originally sealed.
The work was also carried out under strict security precautions and under the supervision of the responsible championship committees.
Which specific components KTM replaced has not yet been officially confirmed. However, much points to the pneumatic valves of the engines as a possible cause of the problems. Yamaha had a similar problem back in 2020.
At that time, a supplier error caused the valves of the M1 engine not to conform to the homologated design, leading to malfunctions. Yamaha also received approval from the competition at that time to open the sealed engines and replace the affected components.
Seven used engines practically refurbished
A MotoGP engine has four cylinders and a total of 16 valves. Once the engines are opened, it is therefore not enough to just replace the presumably faulty valves. Other components such as washers, seals, and lubricants must also be renewed in this context.
Thus, the seven power units opened by KTM are technically in a condition after the overhaul that practically makes them new engines again, even though they had already completed some race deployments before.
Until the permitted opening of the engines, KTM had recently responded to the occurring problems with a more cautious strategy. Depending on the track characteristics, the manufacturer reduced the power or engine speed of the engines at some Grands Prix to minimize the risk of further failures. Whether this restriction will still be necessary after the overhaul is currently open.
The measure is particularly important for Pedro Acosta, who had to endure unexpected engine problems several times in the current MotoGP season. The incident in Montmelo was especially dramatic when his KTM suddenly failed, leading to a serious accident with Alex Marquez, who collided with him.
Since then, Acosta had to compete with reduced engine speed. Therefore, KTM deployed numerous engineers and technicians when opening the engines, who worked practically around the clock to make all necessary changes.
Acosta particularly affected: Four engines overhauled
The focus was on the four power units in Acosta’s pool. The Spaniard had used six engines so far this season. Two of them have now been removed from his rotation. This leaves him with four overhauled engines and two other units that are still unused.
Acosta’s engine strategy shows how the problem developed over the course of the season: At the first five Grands Prix of the year in Thailand, Brazil, the USA, Spain, and France, engines 1 and 2 were initially used.
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At the sixth race of the season in Montmelo, Acosta again used engine 1 and additionally put engine number 3 into operation. In Italy, he continued to rely on units 1 and 3 and also opened engine number 4. At the Hungarian Grand Prix in Balaton Park, engine 1 remained in use, while engine 4 was also used and engine number 5, another new power unit, was started.
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In the Czech Republic, engines 3 and 5 were used. Additionally, engine number 6 was used. After this race, however, KTM decided to remove units 5 and 6 from the rotation. The reasons for this were not explained in detail.
At the race in the Netherlands, Acosta used engines 2 and 3. At the Sachsenring, the Spaniard then returned to units 1 and 2.
There is currently no detailed information about the engines Acosta used at the British Grand Prix in Silverstone. However, it is certain that since units 5 and 6 were removed from the rotation, engines 1 to 4 belong to the units that have now been opened and overhauled.
Engines 1 and 2 are particularly interesting. They were used most frequently with nine and seven Grands Prix and now receive a comprehensive technical “rejuvenation” through the replacement of the relevant components.
KTM competitors so far without comparable problems
There are currently no comparable engine problems among the main competitors. The Aprilia duo Jorge Martin and Marco Bezzecchi each brought five engines to the track up to and including the German Grand Prix.
One of these units has already been removed from the rotation. This leaves both with three new and four already used engines for the rest of the season.
Ai Ogura from Trackhouse-Aprilia as well as the Ducati factory riders Marc Marquez and Francesco Bagnaia have also each used five engines. Unlike KTM, all five units remain in their rotation.
Fabio Di Giannantonio from the VR46-Ducati team has only opened four engines so far. Accordingly, he still has four completely new units.
At the other end of the statistics is KTM factory rider Brad Binder. The South African has already raced with six of his engines and has removed three of them from the rotation – one more than his teammate Acosta.
Yamaha has also already sorted out several units. Toprak Razgatlioglu and Alex Rins have each lost three and two engines from their pool, respectively. However, due to the applicable concessions, Yamaha has ten instead of only eight engines per rider available, unlike the other manufacturers.
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For KTM, the upcoming Grand Prix in Aragon will likely show whether the elaborate overhaul actually brings the hoped-for effect. Especially for Acosta, it is eagerly awaited whether the engines can be used again without the previous speed and power restrictions.
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