KTM 500 EXC 2014: THE POWERHOUSE
SUPERIOR CHASSIS
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.
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. For the 2014 model year, our engineers have revised the chainguide for the benefit of higher functional reliability, while simultaneously reducing the weight.
SUSPENSION/DAMPING
Flexibility foremost: 48 mm open-cartridge fork with fully adjustable spring preload, rebound and compression damping. Each model is individually tuned. Newly developed high-performance fork oil and new seal rings provide improved responsiveness with more constant damping properties. Its set-up – designed especially for enduro use and optimised on some models – ensures maximum traction and plenty of comfort. Naturally, rebound and compression damping can be adapted individually to the track and rider in no time at all – they can even be adjusted separately for high and low speed on the rear shock absorber.
TRIPLE CLAMPS
The lower triple clamp has been modified for optimum attachment of the new front fender. Thanks to its new contour and attachment with two bolts from the front and two from below, the new fender boasts significantly higher stability.
BODYWORK
BODYWORK
Spoiler, airbox cover and front fender, including headlight mask and headlight, have all been restyled for 2014. In doing so, we focussed on designing the new bodywork ergonomically and functionally in such a way that the whole motorcycle is in perfect harmony with the rider down to the very last detail. But other aspects have also been considered. For example, the designers ensured there is no ribbing whatsoever on the inside of the new front fender, thereby preventing mud build-up. Nevertheless, thanks to its skilfully selected contour and its modified attachment to the lower triple clamp, the new fender is up to 50% stiffer than its predecessor.
AIR BOX
At the same time, the revised design of the airbox guarantees optimum protection of the air filter from dirt plus maximum air throughput for the highest performance. New airbox covers are manufactured in a 2-component process with new in-mould graphics. The fixing for the left cover has been further improved to enable even quicker replacement of the twin-air filter, which is held more securely in place with an optimised clasp. And the filter can still be replaced 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 handlebar can be fixed in a choice of four positions. Redesigned handguards made from ultra-sturdy 2-component plastic have been fitted for the 2014 model year, ensuring more efficient hand protection. The newly installed clutch armature from Brembo has been adapted to the appearance of the brake armature.
GRAPHICS
A new, refined graphic design with clear lines underlines the high demands made of a modern, state-of-the-art offroad motorcycle.
WHEELS AND BRAKES
WHEELS
The wheels feature CNC-machined hubs, high-end Excel rims and black coated spokes with lightweight aluminium nipples, allowing the 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. A new handbrake armature has been employed for the 2014 model year, with new remote reservoir, smaller brake piston diameter and a new lever with optimised lever kinematics. As a result and thanks to optimised sintered brake pads (Toyo B169), the performance and application of the front brake have been perceptibly improved again.
ENGINE
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.
CYLINDER HEAD
The cylinder head is equipped with an overhead camshaft, which has been reduced in weight by approx. 10% for MY 2014, as well as two titanium intake valves and two steel exhaust valves. The weight-optimised valve train (40% lighter valve springs and valve spring retainers) results in lower friction and therefore both improved performance and reduced engine braking. Designed in accordance with the latest racing standards, a reinforced cylinder head gasket now also guarantees even greater durability in extreme conditions. The auto-decompressor has also been reinforced to optimise its durability.
PISTONS
The lightweight, forged piston with a box-in-box design is equipped with the high-performance piston rings of the 450 SX‑F for MY 2014. The benefits are reduced oil consumption and optimised performance.
CRANKSHAFT
The crankshaft with 72.0 mm stroke and ultra-light connecting rod is manufactured by Pankl from a special, high quality steel. As on the other EXC-F models, it is equipped with a plain bearing in the lower conrod eye. The previous needle bearing is replaced with two press-fit bearing shells that run directly on the crankshaft's crank pin. This design enhances the durability of the engine, thereby enabling an extension to the service intervals for the crankshaft.
ENGINE MANAGEMENT SYSTEM (EMS)
The engine management system 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 six-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
The single-piece outer hub of the further optimised DDS (Damped Diaphragm Steel) clutch is machined along with its primary gear from a solid block 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. Furthermore, an optimised inner clutch hub improves the durability of the clutch. Finally, in conjunction with the diaphragm spring, the hydraulic clutch actuation system from Brembo ensures very smooth and very precise clutch control.
STARTER
The 500 EXC is equipped as standard with both kickstarter and electric starter. Positioned behind the cylinder, the electric starter is well protected.
The 500 EXC is undisputedly one of the most powerful enduro machines in its class. The combination of light weight and high-capacity, high-tech, SOHC four-stroke technology is the right choice for all those in the E2 and E3 classes seeking maximum four-stroke performance combined with playful handling. These powerhouses are regarded without doubt as the benchmarks in their classes.
TECHNICAL DETAILS
ENGINE
| Design | 1-cylinder 4-stroke engine, water-cooled |
|---|---|
| Displacement | 510.4 cm³ |
| Bore | 95 mm |
| Stroke | 72 mm |
| Starting aid | Electric starter/Kickstarter |
| Engine lubrication | Forced oil lubrication with 2 Eaton pumps |
| Primary ratio | 32:76 |
| Secondary ratio | 14:50 (13:50) |
| Cooling system | Liquid cooling system, continuous circulation of cooling liquid with water pump |
| Clutch | Wet multi-disc clutch DDS / Brembo hydraulics |
| Ignition system | Contactless, controlled, fully electronic ignition system with digital ignition timing adjustment |
CHASSIS
| Frame | Central tube frame made of chrome molybdenum steel tubing |
|---|---|
| Forks | WP Suspension Up Side Down 4860 MXMA PA |
| Shock absorber | WP Suspension PDS 5018 DCC |
| Suspension travel Front | 300 mm |
| Suspension travel Rear | 335 mm |
| Brake system | Disc brakes, brake calipers on floating bearings |
| Brake discs - diameter Front | 260 mm |
| Brake discs - diameter Rear | 220 mm |
| Chain | 5/8 x 1/4" |
| Steering head angle | 63.5° |
| Wheelbase | 1,482±10 mm |
| Ground clearance, unloaded | 345 mm |
| Seat height, unloaded | 970 mm |
| Total fuel tank capacity, approx. |
9 l Unleaded premium fuel (95 RON) |
| Weight without fuel, approx. | 111.5 kg |
