The Most Popular All-Terrain Tire Just Got Better

Next time you drive anywhere—to work, school, your local ski area—check the tires on the vehicles around you and more than likely you’ll see a set of BFGoodrich KO2 all-terrains (ATs) rolling by. Long loved for their performance and looks, the KO2 is the most ubiquitous all-terrain tire on the market, and for good reason.

Made to perform well in all conditions the KO2 has helped thousands of drivers plow through snow, mud, and sand on the way to their next adventures. Here at Outside we’ve hammered home many times that a quality tire is the most important upgrade you can make for off-road performance, and we’ve always rated the KO2 as a good investment.

After 10 years of KO2 popularity, BFG recently released the KO3, which moves the tire forward in several ways. I’ve been testing the tires for months on my 2024 Tundra in Albuquerque, New Mexico, and also had the chance to drive them during an off-road adventure in Alaska. I’ve been impressed with the performance over thousands of miles of pavement and every off-road condition imaginable. Whether tearing up muddy roads, crawling up high-clearance 4×4 routes, trying to park my car in deep snow banks, or cruising freeways at 75 mph, the KO3 has always felt like a good choice.

To learn how the BFG engineers took an already top-performing tire like the KO2 and made it even better, I sat down with two people who were instrumental in the design and launch of the BFGoodrich KO3—Brandon Sturgis, BFG’s global product manager, and Jon Jewell, one of the company’s product design and industrialization engineers. Sturgis and Jewell started the conversation by listing all the spots where they wanted to see improvement: wear, road noise, and performance on gravel, snow, mud, and wet spots.

Improved Durability

Better wear was a key focus for two reasons. First, the BFGoodrich KO3s are expensive so buyers want their investment to last. Second, KO3 buyers use the tires hard and don’t want them to fail because of uneven or fast wear. BFG made the KO3 15 percent more durable than the KO2 by using a new rubber compound and packing the lugs closer together to create a denser contact patch where they meet the road. The rubber compound is formulated for supposed to be better at absorbing the contact from the road, which creates less wear, and the denser contact patch reduces the stress on the individual lugs.

The KO3 comes with the same 50,000-mile warranty as the KO2, but thanks to the more durable build, the KO3 is rated for today’s increasingly powerful trucks and SUVs that put extra wear on tires—like my Tundra.

With the explosion of overlanding in the U.S. and across the world, BFG saw that the KO2s were spending increased time on rough dirt roads. For the KO3s they wanted to cut down on what’s called “chip and tear,” where parts of the lugs get sliced by the gravel and eventually tear away, reducing the tire’s effectiveness and longevity. BFG’s new KO3 rubber compound allows for increased elastic deformation in the lugs so that they can conform to gravel in the road instead of getting shredded. The lug pattern is also designed so that no one individual lug takes a particular beating—all the grouped lugs on each section of the tire work together to absorb the impact.

Sidewall durability is important on an all-terrain tire because sidewall punctures are pretty much impossible to repair. To ensure drivers don’t get stranded with the KO3, BFG built an extra-burly sidewall into the tire that uses technology from their Baja T/A KR line of tires that are used on high-powered, off-road race vehicles.

More Versatile Performance

Those of us who love to ski, or just enjoy exploring in winter, will be happy to hear that the KO3 improves snow traction thanks to a new sipe design. Sipes are the slits in the lugs that open as the tire makes contact with the ground, allowing the lug to bite into the snow. The sipes on the KO3 go the full depth of the lug, creating a large bite. Inside the sipe there’s an egg carton-like structure that keeps the two sides of the lug from deforming when it hits the road, enabling a better bite and more even wear that allows the lugs to last longer.

“We wanted to make sure we created a tire that performed just as well in the Texas summer as it does in the Canadian winter,” Jewell said.

BFG makes a tire called the KM3 that’s designed specifically to excel in mud, but the multiple-use KO3 does amazingly well—something I saw as we powered through puddles in Alaska. That’s thanks to a more aggressive lug pattern on the side of the tire and mud-phobic bars between the lugs that help release the suction that builds up when mud gets pushed in between the lugs so that it can fall out and the lugs can go back to biting into new mud down the road.

To ensure the KO3s stay planted on wet pavement, the lug pattern was designed to push water out of the way when the rubber meets the road. The new rubber compound, along with the sipes, also help create grip so that you can cruise down the freeway safely, rain or shine.

Reduced Road Noise

Since most drivers spend the majority of their time on pavement and don’t want to listen to a constant hum, BFG engineers created a pattern where not all the lugs hit at the same time, designed lugs that give off variable pitches, which creates a less ferocious noise, and tuned some lugs to cancel each other’s noise out. In my testing, I found the tires are louder than a regular street tire, but not by much.

All of this engineering takes time, of course, and Sturgis said BFG first started developing the KO3 back in 2015. The KO03 also builds on the 10-year run of the KO2, and the 15 year run of the original KO before that.

BFG tested the KO3 for years before launching. The ultimate test comes when they sling their tires on buggies and trucks running the Score Baja 500 and the Baja 1000—two of the world’s most famous off-road races. They’ve had a lot of success: Over the years BFG-equipped vehicles have won 35 Baja 500s and 343 Baja 1000s. The KO3s were used on the Baja Challenge 1000-winning buggies that won the 2022 San Felipe 250 and the 2023 Baja 1000. 2021, 2022, and 2023 Baja 1000 races.

I didn’t get to ask Jewell and Sturgis about when BFG plans to launch the KO4, or whatever iteration of the all-terrain tire they have up their sleeves next. They both, however, hinted that, as product people, they’re always watching how the current product is performing, then weighing that with the development of vehicles and how people want to adventure.

“I can tell you that ideation never stops, and at BFG we think there is no reason to not apply what we’ve learned as soon as we can,” Jewell said.