Motorcycle specifications KTM500 EXC 2014 L'ultime assaut

the 500 EXC is unquestionably one of the most powerful enduro machines in its class. The combination of light weight and a high-tech, large-displacement SOHC four-stroke engine is the right choice for those who want the maximum performance of a four-stroke combined with the playful handling of the E2 and E3 categories. This powerhouse is undoubtedly the benchmark in its class.

oIL SYSTEM

The engine features two oil pumps and a common oil circuit. A delivery pump ensures reliable lubrication of the connecting rod, piston, balancer shaft and valve train. It also cools the ignition and lubricates the clutch. A vacuum pump draws oil from the crankcase and lubricates the gearbox.

eNGINE

Developed for rugged enduro use, the 510.4 cm3 SOHC engine features an extremely compact design, ease of maintenance and excellent robustness for minimum weight. With Keihin fuel injection, it offers unrivalled performance and handling, specifically targeted for enduro use.

cRANKSHAFT

The overhead camshaft of the 2014 model year is around 10% lighter and drives two titanium intake valves and two steel exhaust valves. The weight-optimized valve train (40% lighter springs and valve spring cups) generates less friction, for better performance and less engine braking. A reinforced cylinder head gasket for the new competition standards now guarantees even greater robustness in extreme operating conditions. The automatic decompressor has also been improved to optimize its robustness.

pISTONS

For the 2014 model year, the lightweight forged piston in Box-in-Box construction features new High-Performance rings from the 450 SX-F. The advantage is reduced oil consumption and optimized performance.

eMBIELLAGE

The connecting rod with its 72.0 mm stroke and ultra-light connecting rod is made by Pankl from high-quality steel. Like other EXC-F models, it features a plain bearing in the lower connecting-rod eye. The old needle bearing is replaced by two pressed bushes which are directly connected to the connecting rod crankpin. This design enhances the engine's durability, thereby extending the service intervals for the connecting rod.

eNGINE MANAGEMENT SYSTEM (EMS)

Keihin's EMS engine management system with electronic fuel injection and 42 mm butterflies ensures spontaneous responsiveness and maximum engine performance. A 196 W oil-cooled generator provides sufficient power for fuel injection, lighting and other consumers. The Map-Select-Switch available in the PowerPart catalog enables various engine characteristics to be selected via the EMS. In addition, an optional User-Setting-Tool lets you use a laptop to access motorcycle data and modify ignition and fuel injection mapping with just a few clicks.

bALANCE SHAFT

For mass balancing, the engine features a balance shaft that also serves as a drive for the water pump.

gEARBOX

The 6-speed gearbox is specially stepped for the characteristics of 500 cm3 engines and for all types of enduro use. It excels in terms of precision and ease of shifting.

dDS CLUTCH

The one-piece bell of the optimized DDS clutch (Damped Diaphragm Steel) is milled from high-tensile steel together with the timing gear. This process guarantees unrivalled reliability, and the compact, rivet-free design of the clutch housing results in a very slim motor. This design also allows the use of thinner steel plates, which also contribute to the clutch's compact dimensions. The spring washer provides additional hub damping: an invaluable advantage in terms of traction and gearbox wear. An optimized drive dog also enhances the clutch's robustness. Finally, the Brembo hydraulically actuated clutch and spring washer ensure easy, controllable progressiveness.

sTART

The 500 EXC is equipped as standard with both kick ignition and an electric starter. The electric starter is well protected behind the cylinder.

fRAME

The modern design of the 500 EXC's frame in lightweight, high-strength chromium-molybdenum steel tubing combines maximum longitudinal rigidity with optimum torsional rigidity. This not only ensures good handling and precise steering, but also excellent ride stability. The new frame not only shines in its new colors, but also clearly sets new standards in terms of weight and stability.

sINGLE ARM

The cast aluminum swingarm has been designed using state-of-the-art calculation and simulation software; the design and wall thickness ensure minimum weight for optimum strength and a perfectly defined flex. For the 2014 model year, engineers have improved the chain guide for greater reliability and reduced weight.

sUSPENSION / DAMPING

Top adaptability: 48 mm open cartridge fork, fully adjustable for spring preload, rebound and compression. Each model is custom-tuned. New high-performance fork oil and seals offer improved response for smoother damping properties. Enduro-targeted settings, optimized for certain models, ensure maximum grip and comfort. Fork rebound and compression can be quickly adjusted to suit rider and track. The rear shock absorber also features separate High-Speed and Low-Speed settings.

fORK TIPS

The lower fork crown has been modified for optimum attachment of the new front mudguard. Thanks to its new shape and mounting with two screws from the front and two from the bottom, the new mudguard is significantly more robust.

bODYWORK

Spoiler, airbox cover, front mudguard, front mask and headlamp have been restyled for the 2014 model. The aim was to create a new, more ergonomic and functional fairing, so that every detail of the bike is in perfect harmony with the rider. But other aspects were also taken into account. For example, the designers removed the ribs on the inside of the new front mudguard, to prevent any accumulation of mud. Even so, the new mudguard, with its cleverly chosen shapes and improved mounting system on the lower fork crown, is up to 50% stronger than the previous model.

aIR BOX

The new airbox design ensures optimum protection of the air filter from dirt, and maximum air flow for enhanced performance. The new airbox covers are manufactured using a two-component process, with new "Inmould" graphics. The fastening and mounting of the left-hand cover have been further improved to allow even quicker replacement of the Twin Air filter, which is better secured thanks to an optimized system. As always, the filter can be replaced without tools. Two additional tabs on the cover also enable it to be secured with screws.

gUIDON

All EXC models are equipped with extremely sturdy Neken tapered handlebars made from solid aluminum alloy. The proven KTM system allows the handlebars to be fixed in a choice of four positions. The 2014 model features new handguards in robust bi-component plastic for more effective hand protection. The new Brembo clutch cover has been adapted to the look of the brake cover.

gRAPHICS

A refined new graphic design with clear lines underlines the uncompromising demands of this modern off-road motorcycle.

wHEELS

Lightweight CNC-machined hubs, top-of-the-range Excel rims and black-coated spokes with lightweight aluminum nipples ensure minimum weight and maximum stability. Maxxis enduro tires have been specially developed for KTM, offering perfect grip and excellent performance.

bRAKES

High-tech brakes from Brembo® have long been standard on KTM off-road bikes, with lightweight Wave disc brakes for optimum braking performance. For the 2014 model year, we've introduced a new brake pod with a new compensation reservoir, a smaller piston diameter and a new lever with optimized kinematics. Thanks to this and sintered brake pads (Toyo B169), front brake performance and dosability have been further significantly improved.

News credit: KTM
Photo credits: KTMimages