KTM has successfully re‑opened and refurbished its MotoGP power units, clearing the way for a return to the Aragon Grand Prix.
Engine Revitalisation in Munderfing
From a covert operation launched last Monday at the Munderfing engine centre—just over three kilometres from Mattighofen—KTM’s engineers and technicians dismantled every unit that had delivered performance issues during the first half of the season.
Each machine was stripped, critical components were swapped – most likely the pneumatic valves that previously caused a Yaml problem in 2020 – and the engines were resealed before being re‑introduced into the programme.
The move was carried out under strict security, with full FIM oversight and approval from the other championship teams, ensuring the process met the series’ safety and technical regulations.
When an engine has been opened, its washers, gaskets, lubricants and other minor parts must also be replaced, essentially turning seven of the open power units into near‑new units with four cylinders and 16 valves each.
KTM’s tactic of limiting engine revs on some tracks has been in place since the problems surfaced, but it is yet unclear whether that restriction will be kept after the recent fixes.
Pedro Acosta’s Engine Story
Acosta has rotated through a fleet of up to eight engines, with six opened to date. Two units have been retired, two are currently opened, and two remain unused.
Acosta’s first five Grands Prix deployed engines 1 and 2. Barcelona saw the rider use engine 1 again while installing a fresh engine 3. Italy kept engines 1 and 3 at work and introduced engine 4. Hungary saw engines 1 and 4 in operation with a new engine 5 added. The Czech Republic ran engines 3 and 5, while adding engine 6. Following the Czech race, engines 5 and 6 were withdrawn. The Netherlands featured engines 2 and 3, and Germany concluded the sequence with engines 1 and 2 again.
No information has emerged about the Silverstone run, but with engines 6 and 7 retired, the currently opened units are 1 through 4, the most heavily used engines slated for revitalisation.
Competitive Landscape of Engine Usage
Aprilia’s Jorge Martin and Marco Bezzecchi have each opened five engines up to the German Grand Prix, discarding one to leave them with three new and four used units. Trackhouse’s Ai Ogura and Ducati’s Marc Marquez and Francesco Bagnaia have employed five units each, retaining all throughout the season. VR46’s Fabio Di Giannantono opened four units, maintaining an equal number of new engines, while Brad Binder (KTM) has opened six, discarding three.
Yamaha’s Toprak Razgatlioglu and Alex Rins have had three and two discarded engines respectively, but concessions have granted them 10 usable units for the remainder of the campaign.
Seasonal Implications Ahead of the Next Race
With the refreshed engines back on board, KTM is positioned to restore the performance ceiling that had been eroded by earlier reliability setbacks. The renewed power units will be tested immediately at Aragon, potentially redefining the battle for the front‑row at the upcoming circuits.
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