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KTM 450 EXC-F 2018:Tame any terrain

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You don’t just become the bestseller. You have to earn it. With mud, sweat and gears. The power-to-weight ratio of its compact DOHC engine is spot on for any terrain and situation. It will answer the call of the wild with precise handling and tough suspension. No matter how mud-caked your face is, that smile will shine through. When you find the end of the trail, you will know what we’re talking about.

ENGINE

Small in dimensions, sky-high on output. The KTM 450 EXC-F’s

fuel-injected SOHC powers the most compact and lightest 450

on the market, while delivering groundbreaking performance

over the entire rev range. Class-leading and cutting-edge: just

the way we like it. And it’s Euro IV homologated, so it’s green,

while they are green with envy.

 

CYLINDER HEAD

A single overhead camshaft controls intake and exhaust

through optimized ports, while a cutting-edge

combustion chamber and water jacket create mind-blowing

power while managing heat. The engine’s four valves rely

on extremely rigid rocker arms. Double lateral brackets fix

the engine to the frame and reduce vibrations.

 

 

E-Starter

 

The KTM 450 EXC-F is fitted with a unique E-starter as

standard, which is a clear advantage when it comes to

crunch time in the heat of battle. A strong starter motor

and a reliable lithium ion battery will fire up your 450

time and time again at the push of a button. To reduce

weight to the minimum, there is no kick-starter system.

You won’t miss it. If by any chance you do, just retrofit

a KTM PowerParts replacement kit to get your kicks.

 

CRANKSHAFT

The KTM 450 EXC-F’s crankshaft utilizes a short connecting rod,

which makes for an overall compact and lightweight engine

with a snappy power delivery. A plain big (bottom) end

bearing with two force-fitted bearing shells runs directly on

the crank pin. The necessary oil feed for this bearing is

ensured by the engine’s pressurized lubrication. This design

is a decisive benefit in terms of the crankshaft service interval,

which can be lengthened due to the plain bearing. So just

pin it, all day long.

 

ENGINE CASES AND COVERS

The design of the die-cast crankcases allows for minimal

weight and a very centralized shaft configuration. This makes

the engine short and compact, while contributing to an

efficient centralization of masses. The engine covers also

feature a solid surface structure, which reduces the wear

caused by the rider’s boots. This way, your

EXC-F will keep looking better longer.

 

TRANSMISSION

The reliable 6-speed transmission features a special surface

treatment on the 2nd, 3rd and 4th gears for solid reliability.

The advanced ´No Dirt´ gear shift lever design prevents dirt

from jamming the joint of the lever and guarantees precise

shifting even in the muddiest conditions. All 4-stroke EXC-F

engines are fitted with a gear position sensor for tailored

engine mapping for each gear. In MY18, the transmission shaft

gets a new C4 bearing that has a bigger overlap in the case.

This means reliability even under extremely hard conditions.

Think GP-level riding. In knee-deep sand. And a new, stronger

shifting star made of MIM steel (metal injected molding)

improves reliability even further.

 

ENGINE MANAGEMENT SYSTEM

The state-of-the-art Keihin engine management system

with electronic fuel injection features a 42mm throttle body.

Thanks to its unique injector position, the engine’s response

gives a whole new meaning to the word ‘instantaneous’. Separate

circuits for cold-starting and idle make on-site adjustments easy.

Push the throttle back when the engine is warmed

up and the cold start mode disengages.

 

 

Balancer shaft

To balance the mass forces, the KTM 450 EXC-F engine uses

a multifunctional, side-mounted balancer shaft, which at

the same time drives the water pump. It has been

balanced to perfection, keeping vibration levels to a minimum,

even while gunning it to the maximum.

 

 

CLUTCH

 

The KTM 450 EXC-F employs the KTM-developed DDS

clutch (damped diaphragm steel) with a wear-free steel

basket and extremely heat resistant clutch plates and new,

nitrated steel liners. This clever design employs a diaphragm

spring instead of the usual coil springs, making for considerably

easier clutch action. A diaphragm spring also leaves sufficient

space for a damping system to be integrated into the clutch hub.

The goal is traction, but durability is as well. Light operation

and telepathic amounts of control are standard with

this hydraulic Brembo actuated clutch.

 

Cylinder and piston

Inside the cylinder, with a bore of 95mm, thumps a forged

box-type piston with an ultra-light piston pin. Its crown

geometry is adapted perfectly to the combustion chamber,

where its rigid structure and low weight shine. Thanks

to low oscillating masses, the engine is as smooth

as it’s powerful.

 

Frame

The high-tech, lightweight chrome-moly steel frame has a knack

for easy handling, outlandish rideability, precise cornering

and excellent stability. You can also count on high torsional

rigidity and low longitudinal stiffness. This results in better

absorption of the energy created from the front and rear

suspension sucking up jumps and bumps. In short: more comfort

and less rider fatigue. Laterally attached, lightweight engine

head stays (the connection between cylinder head and frame)

contribute to a reduced vibration level. Two threaded inserts in the

lower cradle tubes allow for safe fixation of an optional

skid plate. The engineers could pull off all that, while making

their frame a big fat kilogram lighter than that of the lightest competitor

on the market. In addition, it is easier to maintain, easier to work

on and supplies more space for the tank and other components.

The bike also features an extra-light subframe made of stable

aluminum profiles, which tiptoes the scales at less than 900g.

 

Footpegs

Sophisticated ´No Dirt´ footpegs prevent jamming up of the pegs,

even when digging in deep ruts. The pegs on the EXC models are

6mm higher than the ones used on SX models, which benefits

ground clearance. But you can swap them at will.

 

Swingarm

This state-of-the-art swingarm allows for an optimized mounting

position of the PDS shock absorber, providing more

progressive action. Furthermore, the cast aluminum design

guarantees lower weight and a perfect flex behavior. The

single-component casting process also eliminates any

inconsistencies and weak points.

 

Brakes

You can’t brake any harder, better, faster or stronger. High-tech

Brembo calipers are combined with lightweight Wave brake

discs. The steel-flex front brake hose has efficient protection

and there’s an integrated channel for the speedometer

cable. First you outrun them, then you outbrake them.

 

Front suspension

The WP Xplor 48 upside-down fork is a split fork developed

by WP in close collaboration with KTM. It is fitted with a spring

on both sides but features separated functions for each

fork leg: compression damping is fitted on the left side,

while rebound is on the right. The forks can easily be adjusted

for compression and rebound with the twist of a dial on the

top of the forks. New outer fork tubes and a reworked setting

make for more sensitivity, improved damping behavior and

a reduced weight. In addition, a sealed hydro-stop guarantees

excellent resistance to bottoming-out. Due to high-quality

materials and a state-of-the-art production process, the

new WP Xplor 48 fork – with approx. 300mm of travel – has

outstanding response and damping characteristics. A comfortable

preload adjuster can be retrofitted and allows for a simple

spring preload setting in three steps without tools

(standard, +3mm, +6mm).

 

Rear suspension

The PDS is kind of a KTM trademark where the shock absorber

is directly connected to the upper side of the swingarm. This

setup boasts the best possible mounting geometry and

provides amazingly progressive damping. The shock absorber

is mounted close to the centerline, which means nearly

symmetrical loads for the swingarm and frame and more

space for the exhaust system. A second piston works

together with a closed cup (instead of a needle) towards

the end of the stroke and is supported by a progressive

shock spring for exceptional bottoming resistance. Various

machined and anodized components and a distinctive WP

color trim make this a valuable, high-end product compared

to the less refined shock absorbers of the competition.

 

 

Triple clamp

The EXC-Fs are fitted with forged triple clamps with an offset

of 22mm, ensuring a solid grip of the fork and precise

handling. The handlebar is adjustable forwards and backwards

over 4 positions, so the EXC-F will fit you like your favorite gloves.

 

Handlebar

KTM engineers know how to handle handlebars. This tapered unit,

made of high-strength aluminum by NEKEN, features a throttle assembly

with a robust aluminum body and easy free-play adjustment.

An ODI volcanized grip sits on the right, while on the left side

of the bar a comfortable ODI lock-on grip requires no glue or

wire to secure it. You can retrofit two interchangeable throttle cams,

for different response characteristics to suit your specific needs.

With an optional map select switch you can select an alternative

power characteristic and activate the unique traction control,

a major benefit under wet riding conditions.

 

Bodywork

KTM R&D, KISKA Design and the factory racers had their

say in shaping the plastics with one goal: complete harmony

between rider and bike. Perfect ergonomics and contact points

provide maximum comfort in movement on the EXC-F. The I-beam

structures of the front and rear fenders guarantee maximum

stability and a low weight thanks to well thought-out construction

and mounting. They also stay cleaner for longer. Clever

brake hose routing on the front number plate prevents

wear and tear.

 

Graphics

New graphics convey the READY TO RACE character

of the 2018 KTM EXC-F model line.

 

Air filter box

The air filter box design offers maximum protection of the air filter

against soiling, while ensuring maximum airflow in a quiet way.

The large Twin Air filter is mounted in a stiff cage, which

at the same time holds the system in place. This design is so

simple; you can pop a fresh one in with a face full of

mud – without tools and in seconds.

 

Fuel tank

The lightweight polyethylene tank has a capacity of 8.5 liters. You

will always be able to see how much fuel remains at a glance,

thanks to the see-through plastic. By pushing the orange release

button in the center of the fuel tank cap, the bayonet mechanism

makes refueling quick and easy. It is fitted with an integrated

fuel pump system and a fuel level sensor. Additionally, the fuel

line features a 90° connector to the tank for better

protection against damage.

 

Exhaust system

Noise limits are a real challenge for every manufacturer. Therefore,

KTM has put a lot of effort into the development of its

exhaust systems. All 4-strokes are fitted with a short high-end

aluminum muffler, mounted as close to the engine as possible.

This means more power, extra mass centralization and better

rideability. An advanced internal design reduces the noise

sufficiently to sit safely below the noise limit, while still providing

the engine response and performance that is expected from a KTM.

 

Wheels

The EXC-F’s wheels feature lightweight, CNC machined hubs and

high-end Giant rims guaranteeing maximum stability at minimum

weight. The wheels are fitted with MAXXIS tires – perfect for

surefooted performance off-road and stability on-road.

 

Battery & Wiring harness

A strong lithium ion  battery breathes life into the engine and

contributes to low vehicle weight. The lightweight battery

and wiring harness are centralized in a compartment above

the air filter box, allowing the mechanic to remove the

subframe without getting in conflict with the electronics.

A happy mechanic is a good mechanic.

 

Cooling system

KTM’s proven cooling system routes the coolant from the

cylinder head through the frame triangle, directly to

aluminum radiators made by WP. Thanks to flow optimized

internal circulation and CFD-calculated ventilation, the system

is superbly efficient. In addition, new radiator protections

improve heat dissipation. Especially in the mud. They are

also integrated into the front part of the shrouds

to protect the radiators in a crash.

 

 

 

TECHNICAL DETAILS

ENGINE

Design 1-cylinder, 4-stroke engine
Displacement 449.3 cm³
Bore 95 mm
Stroke 63.4 mm
Starting aid Electric starter
Transmission 6-speed
CO2 emissions  82.3 g/km
Clutch Wet, DDS multi-disc clutch, Brembo hydraulics
Fuel consumption  3.55 l/100 km
EMS Keihin EMS
   

 

CHASSIS

Frame design Chrome-molybdenum steel central-tube frame
Rear suspension  WP Xplor PDS shock absorber
Suspension travel Front 300 mm
Suspension travel Rear 310 mm
Front brake
Disc brakes
Rear brake Disc brakes
Brake discs - diameter Front 260 mm
Brake discs - diameter Rear 220 mm
Steering head angle 63.5°
Wheelbase 1482±10 mm
Ground clearance, unloaded 355 mm
Seat height, unloaded 960 mm
Tank capacity (approx.) 8,5 l
Weight READY TO RACE (without fuel) 106 kg
   
   

 

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