KTM has emerged from one of the most difficult periods in its MotoGP project after a serious engine reliability crisis threatened to derail its 2026 season.
Motorsport Director Pit Beirer described the episode as a period that “almost killed us” and called it the “most horrible time” the team has experienced since entering MotoGP.
The crisis came at a particularly difficult moment for KTM. After dealing with financial uncertainty, the manufacturer had begun rebuilding its racing operation and appeared to be heading towards greater stability. Instead, a series of engine failures exposed a major reliability problem with its RC16.
The situation reached a critical point at the Italian Grand Prix in Mugello. After one engine failure, two more KTM power units failed on the same day, leaving the team struggling to understand what was happening.
The problem was made even more difficult by MotoGP’s engine freeze regulations. KTM, like Ducati and Aprilia, was required to use a homologated engine specification, with changes restricted to areas such as safety and reliability.
With the engines sealed, KTM could not simply open them up and begin changing components. Beirer admitted the team initially found itself in a frustrating position because engineers did not know where to begin investigating the failures.
“You don’t understand it and you don’t know where to start,” Beirer said.
Source: KTM
KTM eventually began testing older engines that had already accumulated significant mileage. Those units continued to operate without suffering the same failures, giving the team an important clue that the problem was linked to newer components rather than the basic engine design.
The investigation eventually traced the issue to a quality problem involving a highly stressed component supplied by an external company. Some of the affected parts were failing after just 50 to 100 kilometres, with Beirer comparing their condition to something as fragile as glass or crystal.
KTM was also dealing with separate electronic and sensor problems during the same period, including an ECU failure. Support from Magneti Marelli helped the manufacturer resolve those issues, adding another layer to an already complicated situation.
Finding the faulty component, however, did not immediately solve KTM’s problem. The manufacturer needed approval from its MotoGP rivals to open the sealed engines and replace the affected parts.
KTM had to provide extensive evidence to show that the request was strictly related to reliability. This included supplier information, serial and batch numbers and X-ray examinations of the components.
The other manufacturers eventually agreed to the request, with IRTA overseeing the process. The approval came between the German Grand Prix at Sachsenring and the British Grand Prix at Silverstone, giving KTM a crucial opportunity to address the issue during the summer break.
Seven affected engines were subsequently opened at KTM’s facility in Munderfing. The defective components were replaced before the engines were resealed and returned to service.
The engine problems had already forced KTM riders, including Brad Binder, to manage their allocations carefully. The team had also been forced to compromise performance, with its bikes noticeably losing straight-line speed at circuits such as Mugello.
Once the repairs were completed, however, KTM began to see a significant improvement on track.
Pedro Acosta was one of the clearest beneficiaries. The Spaniard quickly rediscovered the pace he had shown before the engine crisis, building a strong run of results from the Aragon Grand Prix onwards.
Acosta's breakthrough came at Spielberg, where he claimed his first MotoGP victory. His resurgence provided a major boost for KTM after months of reliability concerns and offered clear evidence that the RC16 could return to competitive form once the engine problem was addressed.
For Beirer and KTM, the priority now is to leave the crisis behind and return to a more normal competitive environment. After months of uncertainty, the manufacturer can finally focus on performance rather than simply keeping its engines running.
