KTM has finally managed to 'revitalize' its MotoGP engines after facing reliability issues throughout the first half of the 2026 season. The operation, described as a 'surgical' procedure, began last Monday at KTM's engine production center in Munderfing, Austria, just three kilometers from their headquarters in Mattighofen.
Engineers and technicians at KTM opened seven engine units that had been a source of headaches. Components suspected of causing failures were replaced, and the units were resealed for use in the remainder of the season, starting with this weekend's Aragon Grand Prix.
This step was made possible after other manufacturers gave KTM permission to open the engines early, as revealed by Motorsport.com on August 7. The process was carried out with utmost discretion, under strict FIM supervision, and details of the replaced components remain confidential. However, strong indications point to the pneumatic valves fitted in each engine.
This valve issue previously affected Yamaha in 2020. At that time, a supplier defect altered the size of the M1's valves by hundredths of a millimeter. Like KTM now, Yamaha then also received approval from other manufacturers to unseal its engines.
Each MotoGP engine has four cylinders and 16 valves. In addition to replacing valves, other elements such as washers, gaskets, lubricants, and other details must also be changed. As a result, the seven opened power units are now practically new components.
Since problems began, KTM had limited engine power in some races depending on circuit characteristics. However, it remains unclear whether the Austrian team will continue this policy after these fixes.
Special attention was given to the four engines used by Pedro Acosta. The Spanish rider experienced several unexpected engine stoppages, including a dramatic incident in Barcelona. KTM subsequently limited the engine revs on his bike. This season, Acosta has opened six units, two of which are already out of rotation, leaving four newly opened and two more still sealed.
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