Motorcycle specifications KTM500 EXC-F Six Days 2017

Do you need big muscles and plenty of watts to take on the grueling Six Days? If you think you've got what it takes, the 500 EXC-F is for you. No other brand in off-road motorsports can match KTM's track record. The SIX DAYS special edition models pay tribute to this success with special performance enhancements and top-of-the-range components. In 2016, the International Six Days of Enduro (ISDE) will be held in Navarre (Spain), and the KTM model range has been equipped to outwit all the pitfalls that these muddy, rocky terrains can present. With its brand-new DOHC four-stroke engine and state-of-the-art chassis, it'll take on any terrain and any opponent with disconcerting ease. Beware! The wild beast is unleashed.

eNGINE

small in size, but giant in performance. Modifications to the 500 EXC-F's fuel-injected engine have made it one of the most compact and lightest 500 cm3 on the market. Featuring a redesigned cylinder head and state-of-the-art electronic fuel injection, this power monster delivers staggering torque across the entire rev range. It's a top-quality engine supported by cutting-edge technologies. And because it's Euro IV-approved, it's kinder to nature.

cYLINDER HEAD

the SOHC cylinder head has been completely revised. Fuel flow through optimized ports is controlled by a new overhead camshaft. The improved water jacket and combustion chamber take care of explosion quality and heat dissipation. The four valves are operated by ultra-rigid rocker arms. Other noteworthy improvements include a narrower timing chain and reduced friction forces on the chain guide. Two new lateral mounting brackets have been introduced to better secure the engine to the frame and reduce vibrations.

cRANKSHAFT

the crankshaft of the 500 EXC-F offers greater rigidity and uses a shorter connecting rod. More compact and lighter, the engine also gains in responsiveness. Comparable in weight to the previous year's model, the crankshaft's inertia is 5% greater, and it benefits from a higher compensation factor that reduces the level of vibration. The crankshaft features a plain connecting-rod 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 design increases engine life and extends crankshaft maintenance intervals - a benefit for the customer in terms of time, effort and cost. The use of metal shims instead of gaskets ensures better sealing and reduces the space occupied by the crankshaft, further refining the engine. For greater compactness, the primary transmission is now shorter (31/76 instead of 32/76) to reduce shaft distance. To increase power and extend service intervals, you can't settle for half measures.

cYLINDER AND PISTON

the shortened cylinder, with a 95 mm bore, 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 500 EXC-F engine uses a side-mounted multifunction balancer shaft that also drives the water pump. perfectly balanced, it minimizes vibrations even at full throttle.

cRANKCASES AND ENGINE COVERS

the all-new design of the molded crankcases offers a much more centralized shaft configuration. Engineers have succeeded in raising the crankshaft by 7 mm and moving it back 9 mm, bringing it closer to the motorcycle's center of gravity. The weight saving amounts to 550 grams. The new engine covers feature an advanced surface structure to prevent premature wear caused by the rider's boots. The engine will continue to shine, day after day.

eNGINE MANAGEMENT SYSTEM

keihin's electronically-injected engine management system features an all-new 42 mm throttle body. Thanks to the injector's unique position, engine response is truly instantaneous. And for added convenience, there are independent adjustment systems for cold start and idle. Once the engine is sufficiently warm, simply lower the throttle to deactivate the cold-start mode.as the proud owner of a SIX DAYS 4-stroke motorcycle, you can increase the power curve and activate the traction control system for a little extra punch. An engine map selectable via the handlebar-mounted switch even enhances the aggressive character of your machine.

eLECTRIC STARTER

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

cLUTCH

the 500 EXC-F uses a DDS (Damped Diaphragm Steel) clutch developed by KTM, featuring a wear-free steel clutch housing and heat-resistant clutch plates. A special feature of this design is the use of a diaphragm spring instead of the usual coil springs, giving the clutch greater flexibility. The diaphragm spring also leaves ample room for a damping system integrated into the clutch hub, to enhance traction and durability. The clutch bell is lighter, the clutch nut has been reworked, and the pressure plate helps optimize oil supply and cooling. Brembo's hydraulic clutch mechanism plays an essential role in the clutch's progressiveness and operation.

gEARBOX

thanks to the low-friction coating of the selector fork, the 6-speed enduro gearbox is a model of precision and smoothness. It features a redesigned selector drum, and the surface has been specially treated for the fifth and sixth gears. The "zero dirt" design of the selector avoids clogging and jamming of the lever joint for smooth, precise shifting. All 4-stroke engines feature a gear sensor that adapts the power curve according to the gear engaged and the terrain. A model of ingenuity, seduction and efficiency.

lIGHTENING: -5 kg

the main objective of KTM engineers when developing the new EXC generation was to reduce weight considerably. The result is clear: the current EXC models are among the lightest and slimmest enduro bikes on the market, despite the fact that they are equipped withthey are now equipped with a highly beneficial electric starter, whereas competing models still have to be kick-started.

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 maneuverability, 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 going over a bump. The ride is more comfortable and less tiring. The dropouts that link the cylinder head to the frame are as light as ever. Mounted laterally, they help limit vibration levels. Two threaded inserts have been provided in the lower cradle tubes to add a shoe, should the need arise. 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 fuel tank and other components. The ultra-light rear section, made of stable aluminum profiles, weighs in at less than 900 grams.

oSCILLANT ARM

the new design optimizes the position of the PDS shock absorber for even smoother engagement. In addition to an attractive weight saving (220 g), cast aluminum offers ideal bending behavior. The one-piece molding process eliminates the imperfections inherent in welding, guaranteeing a more homogeneous manufacturing quality.

fOOTREST

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

bRAKES

more responsive, more efficient and more powerful than ever, Brembo brakes will cope with any situation. These little jewels of technology are combined with Wave discs renowned for their lightness. The rear brake pedal has been lengthened by 10 mm, and the brake caliper piston is now smaller, for better braking proportioning. The stainless steel front brake hose has a protective sheath with a cable guide for the speedometer wire. Optimum braking power is a must when you intend to push your machine.

fRONT SUSPENSION

another interesting new feature on this bike is the WP XPlor 48 inverted 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 30-notch knob above the plunger. To reduce the risk of bottoming, the fork features a longer, sealed hydraulic stop. High-quality materials, ultra-sophisticated production process, 300 mm travel, 200 g weight savings over the previous model : nothing has been left to chance to make the new XPlor 48 fork the ultimate in responsiveness and damping. Available as an option, the new preload adjuster allows the triple compression spring to be adjusted without the need for tools. Operation is disconcertingly simple.

rEAR SUSPENSION

the bike is equipped with an all-new PDS XPlor shock absorber developed by WP. A true KTM trademark, the progressive damping system (PDS) has proved its worth time and again. As the shock absorber is connected directly to the upper part of the swingarm, it does away with the linkage system. This set-up has been redesigned with the new frame and swingarm architecture in mind. It's based on impeccable geometry and even more progressive damping. The body, also completely redesigned, features a smaller piston and a larger chamber. To save precious grams, the piston diameter has been reduced from 50 to 46 mm, the overall length has been cut by 2.5 mm and the shock absorber stroke has been reduced by 4 mm. As the shock absorber has been moved 5 mm 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 stop), is supported by a progressive-action spring. End-of-stroke heels are a thing of the past. This part has been lightened by over 600 grams. With its various machined and anodized components and its characteristic WP color scheme (black chamber, white spring and silver body), this ultra-sophisticated shock absorber makes a strong impression.

gUIDON

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 an innovative throttle response mechanism, a sturdy aluminum handlebar 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, you can adapt the throttle response to suit your riding style. Engine maps selectable via the handlebar-mounted switch modulate the engine's power curve and enhance the bike's spirited character. To ensure efficient transfer of traction to the ground, the bike features a revolutionary traction control system, activated at the touch of a button.

fORK TIPS

the new generation features machined, orange-anodized fork crowns with a 22 mm offset for improved fork support and even more precise front-end behavior. Four positions are possible on this Enduro bike to move the handlebars forwards or backwards for a perfect grip.

fUEL TANK

thanks to its transparent plastic, the ultra-light 8.5-liter polyethylene fuel tank lets you know at a glance how much fuel is left. To refuel, simply press the orange button in the center of the cap to open the bayonet mechanism. Four-stroke models feature an integrated fuel pump system and an additional fuel level sensor. The 90-degree fuel connection on new models further enhances protection against damage.

aIR FILTER HOUSING

Equipped with new intake snorkels, the air filter housing has also been redesigned to better protect the air filter from clogging and ensure optimum airflow with complete peace of mind. The cage housing the new, extra-large Twin Air air filter is totally rigid, ensuring that the system remains firmly in place. The design is so simple that you could replace the filter even with your face covered in mud. And without the need for any tools. And in a matter of seconds.

eXHAUST

complying with the noise emission levels recommended by the FIM is a real challenge for all manufacturers. That's why KTM has spared no effort to develop a state-of-the-art exhaust system. All four-strokes feature new manifolds and a shorter 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 FIM-recommended thresholds, while guaranteeing maximum rider sensations.

wHEELS

when it comes to wheels, KTM engineers know their stuff. Featuring ultra-light CNC-machined hubs and top-of-the-range Giant rims, these wheels guarantee maximum stability despite their limited weight. To top it all off, they're fitted with the latest generation of Maxxis tires. In addition to improved puncture resistance, the rear tire features a specially designed profile and internal structure to enhance grip in wet conditions. Whatever the terrain, these tires deliver maximum traction.

cOOLING SYSTEM

kTM's proven cooling system circulates coolant from the cylinder head through the frame triangle to the new aluminum WP radiators, equipped with a new cap system and made of a stiffer alloy. Its incredible efficiency is due to improved internal airflow management and advances in ventilation thanks to CFD (Computational Fluid Dynamics) calculations. Given their phenomenal power, the 450 and 500 EXC-F models feature a cooling fan as standard, controlled by the control unit. Well thought-out radiator guards integrated into the front spoilers are particularly useful in the event of an impact.

sADDLE

tailored to provide a comfortable support surface for enduro riding, this ultra-strong SIX DAYS saddle lets you tackle any terrain with disconcerting control and minimal fatigue all day long.

bATTERY AND WIRING HARNESS

all EXC-F engines feature a proven electric starter - a KTM exclusive and a major advantage in motocross competition. The electric starter is combined with an ultra-compact lithium-ion battery claimed to weigh 495 g, 1 kg less than a conventional battery, despite being three times more powerful. And because it's so reliable, the kick starter is a thing of the past. The battery and wiring harness are now grouped together in a compartment above the air filter housing, to avoid interference with the electrical circuit when removing the rear frame.

bODYWORK

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 contact points for the rider have been carefully designed for maximum freedom of movement. The lowered saddle offers superior comfort, especially at the rear. The special shape of the front and rear mudguards is a perfect example of intelligent design: thanks to a well-thought-out structure and assembly, these mudguards guarantee maximum stability, while being lighter at the same time. Better still, they stay clean longer. The headlamp plate is also a model of ergonomics. And what more can we say about the trick used to prevent the brake hose from causing ugly scratches?

News and media credits: KTM