KTM 500 XC-W

The 500 EXC is one of the most powerful standard production Enduro racing machines available on the market. The combination of light weight and high-capacity, high-tech, SOHC 4-stroke technology is the right choice for all those seeking maximum, yet controllable 4-stroke performance. Combined with playful handling, this powerhouse is regarded without doubt as the benchmark in its class.

OIL CIRCUIT
The engine is equipped with two oil pumps and a common oil circuit. A pressure pump supplies reliable lubrication to the crankshaft, piston, balancer shaft and valve controls. It also ensures cooling of the ignition and lubrication of the clutch. A suction pump draws oil from the crankcase and uses it to lubricate the transmission.

ENGINE
Developed for tough enduro conditions, the 510.4cc SOHC engine is characterised by an extremely compact design, very easy maintenance and outstanding robustness, with weight kept to a minimum. Together with the Keihin fuel injection system, this results in unrivalled performance and rideability - specially designed for enduro use.

STARTER
The 500 EXC is equipped as standard with both kickstarter and electric starter. Positioned behind the cylinder, the electric starter is well protected.

CYLINDER HEAD
The cylinder head is equipped with an overhead camshaft. This actuates two titanium intake valves plus two steel exhaust valves. The weight-optimised valve train ensures low friction and therefore both improved performance and reduced engine braking.

PISTON
The lightweight, forged piston with a box-in-box design is equipped with the high-performance piston rings of the 450 SX-F. The benefit is minimum oil consumption and top performance.

CRANKSHAFT
The crankshaft with 72 mm stroke and ultra-light connecting rod is manufactured by Pankl from a special, high quality steel. As on the other 4-stroke models, it is equipped with a plain bearing in the lower conrod eye. Two press-fit bearing shells run directly on the crank pin. The engine's direct pressure lubrication system ensures the necessary oil supply for this bearing. This design improves the durability of the engine, thereby enabling an extension to the service intervals for the crankshaft, a benefit for the customer in terms of time, effort and cost.

ENGINE MANAGEMENT SYSTEM (EMS)
The engine management system (EMS) from Keihin, with electronic fuel injection and 42 mm throttle body, ensures spontaneous responsiveness and maximum engine performance. An oil-cooled, 196 W alternator provides sufficient power for the fuel injection system, lights and other electrical loads. Various engine characteristics can be selected via the EMS, with a map-select switch available as a PowerPart. Furthermore, a user-setting tool (also available as an option) allows data to be read from the bike by laptop and the mapping, ignition and fuel injection to be modified in a matter of a few mouse clicks.

BALANCER SHAFT
To counterbalance the inertia forces, the engine has a balancer shaft that acts simultaneously as a drive for the water pump.

TRANSMISSION
The 6-speed transmission is designed specifically for the engine characteristics of the 500cc engine and for every type of enduro use. It excels with precise and easy shifting.

DDS CLUTCH
For MY 2015, the DDS clutch (Damped Diaphragm Steel) is equipped with a further refined, lighter, single-piece basket, which together with its integrated primary gear, is machined from a single solid billet of high-strength steel. This process guarantees unbeatable reliability and allows the engine to be extremely narrow thanks to the compact, rivetless design of the outer clutch hub. In addition, this design allows use of thin steel discs, which also contributes to the compact dimensions of the clutch. The diaphragm spring enables implementation of an additional hub damping mechanism - a benefit in terms of traction and gearbox wear. Finally, in conjunction with the diaphragm spring, the hydraulic clutch actuation system from Brembo ensures very smooth and very precise clutch control.

FRAME
The modern frame design of the 500 EXC, comprising lightweight, high strength, chrome-molybdenum steel section tubes, combines maximum longitudinal stiffness with optimum torsional stiffness. It guarantees easy handling and precise steering behaviour, as well as excellent ride stability. So the new frame not only shines with the new colour, it also clearly represents the benchmark in terms of weight and stability. The frame colour shines in MY 2015 in the same orange as the KTM factory racing team, making the styling even more attractive. Moreover, it's easier to maintain and provides more space for mounting the fuel tank and other components. Thanks to the frame design and in conjunction with the rear PDS damping system, shocks at the rear wheel are absorbed and dissipated optimally.

SWINGARM
The cast aluminium swingarm has been developed with state-of-the-art calculation and simulation software and constructed, in terms of design and wall thickness, for minimum weight with optimum stiffness and precisely defined flexibility.

SUSPENSION/DAMPING
The KTM 500 EXC has its own individual suspension setting, optimally tuned to weight and engine. The high-quality WP suspension components have been specially designed for enduro use. They ensure maximum traction and plenty of comfort. At the rear, a PDS shock absorber from WP Suspension works with a direct linkage to the upper side of the swingarm. The wide range of setting options for rebound damping and high- and low-speed compression damping are standard on KTM bikes.

TRIPLE CLAMPS
The triple clamps have been specifically designed for enduro use and ensure precise handling thanks to their supporting of the fork flex. The rider receives precise feedback from the front wheel, even in the toughest terrain, thereby increasing riding safety and speed.

BODYWORK
The bodywork has been designed ergonomically and functionally in such a way that the whole motorcycle is in perfect harmony with the rider down to the very last detail.

AIRBOX
At the same time, the ingenious design of the airbox guarantees optimum protection of the air filter from dirt plus maximum air throughput for the highest performance. The airbox covers are manufactured in a 2-component process with new in-mould graphics. The filter is replaced very quickly, without any tools. Furthermore, two additional tabs on the cover allow it to be secured with bolts if desired.

HANDLEBAR
All EXC models are equipped with an extremely sturdy, tapered Neken handlebar made from high-strength aluminium alloy. In accordance with the proven KTM standard, the black anodised handlebar can be fixed in a choice of four positions. The handguards are made from a new material in MY 2015 in order to achieve even greater impact resistance.

SPEEDO
The new speedo from MAE integrates all control lights, except those for the turn indicators, into a single component. This provides the cockpit with a cleaner and tidier appearance and makes the available information clear and easy to read.

EXHAUST SYSTEM
Light and robust. The aluminium silencers on EXC models are renowned for their outstanding performance, while keeping noise to a level well within FIM rules. For MY 2015, the 500 EXC receives a new silencer with a full-length perforated pipe to reduce the noise level and further improve performance.

WHEELS
The wheels are equipped with new, black, 7050 T6 aluminium Giant rims, black coated spokes with lightweight aluminium nipples and lightweight CNC-machined hubs, allowing highest levels of stability to be achieved while keeping weight to a minimum. The fitted Maxxis enduro tyres have been specially developed for KTM and excel with perfect traction and outstanding performance.

BRAKES
High-tech brakes from Brembo have always been standard equipment on KTM offroad bikes and, together with the lightweight wave brake discs, they are the measure of all things in terms of brake technology. As the best brakes in enduro sport, they remain unchanged for MY 2015.