Motorcycle specifications KTM500 EXC-F 2018 Woodcutter

The ultimate in strength. A machine for enduro warriors. The KTM 500 EXC-F is undoubtedly one of today's fastest dual-purpose bikes, but this monster of power is surprisingly docile in use and easy to tame. With its single overhead cam 4-stroke engine and state-of-the-art chassis, it's ready to take on any terrain. One step ahead Beware! The wild beast is unleashed.

engine

small in size, but giant in performance. The fuel-injected engine of the KTM 500 EXC-F is undoubtedly one of the most compact and lightest 500 cm3 on the market. Featuring a single overhead camshaft cylinder head and state-of-the-art electronic fuel injection, this power monster delivers staggering torque across the entire rev range. A top-quality engine served by cutting-edge technologies.

cylinder head

the single overhead camshaft controls intake and exhaust via optimized ports. The state-of-the-art combustion chamber and water jacket take care of combustion quality and heat dissipation. The four valves are operated by ultra-rigid rocker arms. To dampen vibrations, the engine is securely fastened to the frame by two side brackets.

crankshaft

the crankshaft of the KTM 500 EXC-F uses a shortened connecting rod. More compact and lighter, the engine also gains in responsiveness. The crankshaft is fitted with a connecting-rod head bearing and two bearing shells press-fitted directly into the crankpin. This bearing is supplied with oil from the engine's pressure lubrication system. This type of design, combined with the connecting-rod bearing, greatly extends the crankshaft's service interval.

crankcases and covers

the design of molded crankcases offers two advantages: maximum weight reduction and a highly centralized shaft configuration, for even greater engine compactness and more efficient weight distribution. Crankcase covers feature a solid surface structure designed to reduce wear caused by the rider's boots.

gearbox

to enhance the reliability of the 6-speed gearbox, the surface of the pinions has been specially treated for 2nd, 3rd and 4th gears. The "zero dirt" design of the selector prevents the lever joint from clogging and jamming, and guarantees ultra-precise gear changes even on the muddiest terrain. All EXC-F 4-stroke engines are equipped with an engaged-gear sensor to adapt the engine's characteristics to each gear. On the AM18, the gearbox shaft features a new C4 bearing with increased radial clearance. This enhances reliability, even under the most demanding operating conditions. Now you can dig yourself out of the sand in the middle of a Grand Prix. The selector made using the MIM (metal injection molding) manufacturing process offers an incomparable level of reliability.

electric starter

the KTM 500 EXC-F is fitted as standard with an electric starter, a decisive advantage when it comes to reducing lap times in competition. Operated at the touch of a button, this ultra-powerful electric starter coupled with a highly reliable lithium-ion battery won't let you down anytime soon. Still with a view to lightening the bike, the kick starter has simply been removed. However, you can always reinstall a KTM PowerParts aftermarket kit.

cylinder and piston

the 95 mm-bore cylinder houses a forged bridge-box piston with an ultra-light piston pin. The geometry of the piston head, perfectly adapted to the combustion chamber, features a rigid structure and reduced weight. Reduced oscillating masses give the engine its smooth, energetic character.

balancer shaft

to balance mass forces, the KTM 500 EXC-F engine uses a multi-function, side-mounted balancer shaft that also controls the water pump. perfectly balanced, it minimizes vibrations even at full throttle.

engine management system

the Keihin electronic injection engine management system features a 42 mm throttle valve body. Thanks to the injector's unique position, engine response is truly instantaneous. And because idle and cold start do not use the same circuits, on-site adjustment is much easier. Once the engine is sufficiently warm, simply lower the throttle to deactivate the cold-start mode.

clutch

the KTM 500 EXC-F uses a DDS (Damped Diaphragm Steel) clutch developed by KTM. a wear-free steel clutch housing, heat-resistant clutch plates and new nitrate-treated steel liners. This clever design is distinguished by the use of a diaphragm spring instead of the usual coil springs, giving the clutch greater flexibility. The diaphragm spring also leaves plenty of room for a damping system integrated into the clutch hub, to enhance traction and durability. The clutch is activated by a hydraulic system manufactured by Brembo, which plays an essential role in the clutch's progressiveness and flexibility.

frame

the high-tech chromium-molybdenum steel frame is a model of lightness, flexibility and handling.the high-tech chromium-molybdenum steel frame, a model of lightness, flexibility and manoeuvrability, offers excellent stability and diabolical precision when cornering. Thanks to its high torsional stiffness and low longitudinal rigidity, this frame better absorbs the energy generated by the front and rear suspensions when jumping or negotiating a bump. The ride is more comfortable and less tiring. The aluminum brackets that link the cylinder head to the frame are as light as ever. Side-mounted, they also help to limit vibration levels and refine the bike's trajectory in bends. The engineers can be proud of their work, as the frame is now one kilo lighter than the lightest competing frame on the market today. Every effort has also been made to facilitate maintenance and free up space for the tank and other components. The ultra-light buckle, made of stable aluminum profiles, weighs in at less than 900 grams.

front suspension

the WP XPlor 48 upside-down fork is a fork with separate damping circuits, developed by WP in close collaboration with KTM. Each fork leg is equipped with a spring and has a different function: the left leg handles compression damping, while the right leg handles rebound. To fine-tune each of these settings, simply turn the knob at the top of the fork. New outer tubes and setups have also improved sensitivity, lightened weight and optimized fork damping behavior. To reduce the risk of bottoming, the fork is equipped with a sealed hydraulic stop. High-quality materials, an ultra-sophisticated production process, 300 mm of travel: nothing has been left to chance to make the new WP Xplor 48 fork the ultimate in responsiveness and damping. The preload adjuster (available as retrofit) makes it easy to set spring preload to three levels (standard, +3 mm, +6 mm), without the need for tools.

rear suspension

a true KTM trademark, the PDS shock absorber is connected directly to the upper part of the swingarm. As a result, engineers were able to mount it in the most appropriate position for even more progressive damping. As the shock absorber has been moved closer to the central axis, the loads exerted on the swingarm and frame are virtually symmetrical. This also frees up space for the exhaust system. The second piston, combined with a cup-shaped limit stop (instead of a needle-type one) and supported by a progressive-action spring, guarantees excellent resistance to bottoming. With its various machined and anodized components and its characteristic WP color scheme, this ultra-sophisticated shock absorber makes a strong impression compared to less well-finished competing products.

swingarm

the latest-crime swingarm optimizes the position of the PDS shock absorber for even smoother entry into action. In addition to weight savings, cast aluminum is ideal for bending. The one-piece molding process eliminates the imperfections inherent in welding, guaranteeing more consistent manufacturing quality.

footrests

sophisticated "zero-dirt" footrests prevent the gear selector from fouling, even when passing through deep ruts. To enhance ground clearance, the gear selector on EXC models is 6 mm higher than on SX models.

brakes

more responsive, more efficient and more powerful than ever, Brembo calipers will cope with any situation. These little jewels of technology are combined with Wave brake discs, renowned for their lightness. The stainless-steel front brake hose features effective protection and a cable guide for the speedo wire. Optimum braking power is a must when you intend to push your machine.

fork tee

eXC-F models feature forged fork tees with a 22 mm offset for improved fork retention and even more precise front-end behavior. Four positions are possible on the EXC-F to move the handlebars forward or backward for a perfect grip.

handlebars

when it comes to handlebars, KTM engineers have always known which way to go. This NEKEN handlebar, with its high-strength aluminum profile, is no exception. It features a throttle response mechanism, sturdy aluminum handlebars and an ultra-simple guard adjustment system. right: an ODI vulcanized handle; left: the ODI lock-on handle, as comfortable as it is practical, thanks to its glueless, wire-free mounting system. And thanks to two interchangeable cams (retrofittable), you can adapt the throttle response to suit your riding style. An optional power curve button lets you change engine mapping and activate the traction control system for extra punch in wet conditions.

styling

kTM factory riders collaborated on the bike's design with KTM R&D specialists and the Kiska design agency, with a single watchword: to create perfect harmony between rider and machine. The result is convincing. Ergonomics and rider contact points have been carefully designed to enhance freedom of movement and comfort on the EXC-F. The special shape of the front and rear mudguards guarantees maximum stability and minimum weight, thanks to a well thought-out structure and assembly. Best of all, they stay clean longer. The clever mounting of the brake hose on the cross front plate also reduces wear and tear.

graphics

the new deco kit confirms the READY TO RACE character of the 2018 KTM EXC-F range.

air filter housing

the air filter housing has been designed to protect the air filter from clogging and ensure optimum air flow. The cage in which the extra-large Twin Air filter is housed is totally rigid, helping to hold the system in place. The design is so simple that you could replace the filter even with your face covered in mud. And all in a matter of seconds, with no tools required.

fuel tank

thanks to its transparent plastic, the ultra-light 8.5-liter polyethylene fuel tank shows at a glance how much fuel is left. To refuel, simply press the orange button in the center of the fuel cap to open the bayonet mechanism. This model features an integrated fuel pump system and fuel level indicator. The 90-degree fuel line connection further protects the fuel tank from damage.

exhaust system

meeting noise emission levels is a real challenge for all manufacturers. That's why KTM has spared no effort in developing innovative exhaust systems. All four-strokes feature a relatively short, high-end aluminum rear silencer mounted as close as possible to the engine. The benefits are threefold: more power, better mass centralization and enhanced driving pleasure. The internal design has also reached a significant degree of sophistication to keep noise levels well below recommended thresholds, while guaranteeing the level of responsiveness and performance you'd expect from a KTM.

wheels

when it comes to wheels, KTM engineers know their stuff. Featuring ultra-light CNC-machined hubs and top-of-the-range Giant rims, the EXC-F's wheels guarantee maximum stability despite limited weight. And because they're shod with MAXXIS tires, the bike is just as comfortable and safe off-road as it is on.

cooling system

kTM's proven integrated cooling system circulates coolant from the cylinder head via the frame triangle to the aluminum radiators supplied by WP. Its incredible efficiency is due to improved management of internal airflow and advances in ventilation thanks to CFD (computational fluid dynamics) calculations. The new radiator protections offer the advantage of better heat dissipation. This is all the more true in the presence of mud. Integrated into the front spoilers, these radiator guards are particularly useful in the event of an impact.

battery and wiring harness

the starter motor is fitted with a powerful lithium-ion battery, which saves a considerable amount of weight compared to before. The battery and wiring harness are grouped together in a compartment above the air-filter housing, to avoid interference with the electrical circuit when removing the buckle. Mechanics and do-it-yourselfers will appreciate this.

Information and image credits: KTM