KTM 500 EXC-F 2018:The Alpha
The KTM 500 EXC-F is the strongest dual sport bike in the world, although that doesn’t mean it’s hard to control. This motorcycle is as lean and civilized as a thoroughbred race horse. But let it rip, and its 4-stroke SOHC engine blasts the cutting-edge chassis across any terrain you choose. Ahead of the competition. No sweat, just glory.
Small in dimensions, sky-high on output. The KTM 500 EXC-F’s
fuel-injected powerhouse makes it the most compact and lightest
500 on the market, while delivering groundbreaking torque and power
figures over the entire rev range thanks to a single overhead camshaft
cylinder head and the latest electronic fuel injection. Class-leading
and cutting-edge: just the way we like it.
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.
The KTM 500 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.
The KTM 500 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 500 time and time again at the push of a button. In order 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.
Crankcases and engine 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.
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.
To balance the mass forces, the KTM 500 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.
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.
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.
The KTM 500 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.
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 aluminum engine head stays (the connection
between cylinder head and frame) contribute to precise
cornering and a reduced vibration level. The engineers
could pull off all that, while keeping 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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
|Design||1-cylinder, 4-stroke engine|
|Secondary gear ratio||14:50|
Wet, DDS multi-disc clutch, Brembo hydraulics
|CO2 emissions||78.8 g/km|
|Fuel consumption||3.4 l/100 km|
Chrome-molybdenum steel central-tube frame
WP Xplor PDS shock absorber
|Suspension travel (front)||300 mm|
|Suspension travel (rear)||
|Front brake||Disc brake|
|Rear brake||Disc brake|
|Front brake disc diameter||260 mm|
|Rear brake disc diameter||220 mm|
|Steering head angle||63.5 °|
|Wheelbase||1482 ± 10 mm|
|Ground clearance||355 mm|
|Seat height||960 mm|
|Tank capacity (approx.)||8.5 l|
|Weight READY TO RACE (without fuel)||106.5 kg|