KTM Emissions, Decoded
KTM Emissions,
Decoded
A clear rundown of every piece of emissions gear on your street-legal 350/500: what each part does, why the factory installs it, and what it means for you.
Why your bike came with all this gear
The 350 and 500 are two of the only genuinely street-legal dirt bikes you can buy new, and that license plate is the whole reason yours leaves the factory carrying gear the off-road-only models (XC-F, XCF-W, SX-F) never get. To earn 50-state EPA approval, plus CARB certification in California, the bike has to pass both emissions and sound limits, so KTM adds several systems built purely to meet those standards. None of it adds performance. What it does add is weight, extra plumbing, and a handful of parts that can clog, leak, or fail. On a dedicated closed-course competition bike, that makes most of it worth removing. Here is each system, what it does, and why it is there.
Six systems, one at a time
Secondary Air System
A reed valve draws fresh air from the airbox and feeds it directly into the exhaust port.
During deceleration and light throttle, some unburned fuel always makes it into the exhaust. Adding fresh oxygen at the port lets that fuel finish burning in the pipe instead of exiting as raw hydrocarbons, which lowers the bike's emissions.
Because it behaves like a deliberate exhaust leak near the head, it is the leading cause of the deceleration popping these bikes are known for. That popping usually gets worse once you fit a freer-flowing exhaust.
Block off the SAS port so no fresh air reaches the exhaust. The 2012 to 2019 kit handles this with an SAS pump plug and crush washer.
Evaporative / Vapor Recovery
A charcoal canister traps fuel vapor that would otherwise evaporate out of the tank. The ECU then opens a purge valve to feed those vapors into the intake, where they get burned.
It started as a California (CARB) requirement and is now standard on US bikes. The goal is keeping fuel vapor out of the atmosphere.
It is bulky plumbing to have on a dirt bike. If the bike tips over, raw fuel can flood the canister, which disrupts tank venting and can starve the fuel pump. Off-road, it is a genuine failure and maintenance point.
Plugs and caps let you remove the canister and its lines. A delete dongle tells the ECU everything is normal, so it does not throw a fuel-injection fault for the missing purge valve.
O2 Sensor & Closed Loop
An oxygen sensor in the header measures exhaust oxygen and lets the ECU adjust the fuel mixture in real time.
It keeps the bike within its certified emissions numbers by holding the mixture lean at idle, cruise, and light throttle.
A lean mixture passes the test but does not make the bike feel good. On pre-2017 models especially, it is a major reason they ran hot, felt abrupt off idle, and stalled easily. KTM improved this significantly on the 2017-and-newer generation, but the sensor and the lean calibration are still there.
A stainless O2 header delete plug seals the sensor bung, and an O2 dust dongle keeps the ECU satisfied. Included in the 2020+ Complete Bundle.
Crankcase Breather
Vents the pressure and blow-by gases that build up inside the engine cases.
Emissions rules require that oily vapor to be routed back and burned rather than vented to the atmosphere, so the stock hose loops it back toward the intake.
Minor on its own, but it is one more line feeding oily vapor back into the intake, which you would rather avoid once the rest of the gear is gone.
A thick-wall, high-temp silicone breather hose that vents it cleanly.
Tank Vent / Rollover Valve
The tank's breather line. From the factory it runs through a check and rollover valve that ties into the EVAP system.
As part of the sealed EVAP system, it controls fuel vapor and prevents fuel from spilling if the bike tips over.
Once the canister is gone, the tank still needs to breathe, or it will vapor-lock and starve for fuel. That calls for a simple vented line rather than the restrictive factory setup.
A check-valve tank vent hose (color of your choice) that lets the tank breathe freely but will not dump fuel when the bike is on its side.
The Factory Fuel Map
The stock ECU is calibrated to hit the specific fuel mixture targets required to pass the emissions test.
Those targets are what keep the bike compliant, so the factory calibration is deliberately lean and conservative, tuned to pass rather than for power or throttle response.
Because it is locked and runs lean, a reflash or aftermarket ECU is the first upgrade for almost everyone. The emissions delete and a proper tune go hand in hand.
Reflashing or swapping the ECU is the first real performance upgrade. Read the KTM Performance Guide for the full rundown.
KTM places reed valves in the intake tract, between the air filter and throttle body, mainly to quiet intake noise for the sound test. They are not emissions equipment, but we still recommend removing them. They work loose and get pulled into the intake often enough that we treat it as a matter of when, not if. Removing them does require a fuel correction, but every one of our tuning options already comes optimized for reed removal, so that side is covered. The bottom-end power loss is minimal.
The bundle also includes a sidestand-return delete bolt. It disables the auto-retracting kickstand, the feature that flips the stand up on its own. This has nothing to do with emissions, it is simply a common race-conversion item that riders like to remove.
All of the above is federally required emissions equipment. Removing it is intended for closed-course competition and race use only, not for a street-registered bike. If your bike is plated and ridden on public roads, this equipment is legally required to stay in place.
Because of CARB rules, these kits cannot ship to California. What you do with a dedicated race bike is your call.
Two ways to delete it
Smog Delete Kit
The essentials. Blocks off the SAS and vapor recovery systems, the two most worth removing, in a quick afternoon job.
- SAS pump plug (2012-2019 bikes)
- Vapor recovery port plug: vacuum screw and washer, or rubber plug
- Charcoal canister frame plugs
- Kickstand auto-return delete bolt
Running a US EPA map? Add the vapor recovery dongle so the FI light stays off.
Shop the Delete KitComplete Smog Bundle
Soup to nuts. Every delete in one box, with the dongle matched to your exact tune. This is what runs on our Baja 1000 bikes.
- Vapor recovery delete plugs, caps, and matched dongle
- Stainless O2 header delete plug and dust dongle (2020+ bikes)
- SAS pump plug and crush washer (2012-2019 bikes)
- Crankcase breather hose
- Check-valve tank vent hose, your color
- Kickstand auto-return delete bolt
Pick your ECU (GET, AIM, Vortex, OEM reflash, or piggyback) and the dongle comes matched to it.
Shop the Complete BundleBoth come in 2012-2019 and 2020-2024 versions, so pick the one that matches your bike.