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2012 KTM 500 EXC

2012 KTM 500 EXC

Model: 12500EXC

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2012 KTM 500 EXC Street Legal

Enough is never enough for all those who are forever seeking a little bit more, KTM has created the 500 EXC. Perfectly controllable power in extravagant proportions, low weight and an unsurpassed chassis characterise an enduro of remarkable versatility: a sensational fighting machine and absolutely reliable workhorse rolled into one, the indisputable benchmark in terms of weight and rideability. At any rate, there's no way to avoid to 500 EXC on the path to the podium in the E3 class.

California Green Sticker and US EPA Off-Highway emission compliant model.

With the 500 EXC's newly developed engine, KTM engineers have created a new dimension: The power unit has been redesigned from scratch and is now more compact, lighter and more powerful than before. Reduced reciprocating weight and a balancer shaft minimise vibration.

The 500 EXC's new, improved silencer not only offers greater volume and a new design, it also reduces noise levels to the stricter standards of the future.

All ports and the combustion chamber have been redesigned in the OHC cylinder head of the 500 EXC's new engine. The new camshaft actuates four valves via lightweight rocker arms. High-quality titanium valves are used on the intake side. As before, the cylinder head cover mounted at an angle simplifies service work.

The 500 EXC's cylinder has been further developed especially for the new engine configuration. The new, 15 % lighter forged piston minimises reciprocating weight and optimises durability at high engine speeds. New, nitrided piston rings ensure highest levels of resistance to wear.

When designing the new crankshaft on the 450 EXC, KTM engineers focussed on reducing the reciprocating weight. Thanks to the new, lighter connecting rod and the new, lighter piston, they managed to achieve minimum vibration, while maximising engine-speed strength.

The 500 EXC's new engine case weighs almost 2 kg (4 lb.) less than its predecessor, although it offers better resistance to damage due to stone impact or falls. This has been achieved by using a high-strength, elastic aluminium alloy and changing from sand-casting to die-casting.

The 500 EXC's new, more compact balancer shaft not only eliminates vibration, but also serves as the drive for the water pump. This intelligent multi-functionality contributes to the compactness and low weight of the 500 EXC's new engine.

The 500 EXC's new engine is equipped with a common oil circuit for engine and transmission, and two oil pumps. A pressure pump lubricates the engine, while a suction pump draws oil from the crankcase, using it to lubricate the transmission and the clutch. At the same time and in conjunction with a steel diaphragm, negative pressure arises in the casing, which boosts the engine power.

The newly developed Keihin engine management system with electronic fuel injection ensures spontaneous responsiveness from the engine. Various engine characteristics can be activated with an optional map select switch.

The 500 EXC's newly developed clutch, with a robust steel cage and transmission-friendly back-damping, makes use of a spring washer for the first time instead of the customary conical springs, hence substantially reducing the operating force. The hydraulic actuation mechanism from BremboŽ facilitates sensitive modulation of the clutch.

The completely revamped frame made from high-quality chrome-molybdenum steel is characterised by even greater lateral stiffness. Furthermore, it is even better at absorbing jolts introduced by the suspension system, whereby the simple handling and comfort of the 500 EXC have been further optimised.

The 450 EXC's new, lighter, cast aluminium swingarm accommodates the shock absorber more centrally, in order to load the swing arms more evenly. The new, 7 mm (0.28 in) longer PDS shock absorber with adjustable rebound and high/low-speed compression damping, and a new setting is installed more flatly, so providing even more progression.

The 500 EXC is equipped with the latest WP upside-down fork with wider adjustment ranges and a new setting. The sensitive responsiveness and outstanding damping of the open-cartridge fork with 48 mm (1.89 in) outer tubes are a perfect complement for the 500 EXC's simple handling and precision.

Practically unbeatable in terms of weight and stability, the new wheels have CNC-machined hubs, Excel rims, zinc/nickel-coated spokes and aluminium nipples. They reduce the unsprung and gyroscopic masses, hence bolstering the simple handling of the 500 EXC.

The 500 EXC's new bodywork with the very slim seat and spoiler lines, plus excellent contact points, perfects the bike's ergonomics, making handling even simpler and more precise. The longer rear fender protects the rider even more effectively from swirled up stones.


Average Customer Review: 5 out of 55 out of 55 out of 55 out of 55 out of 5 1 Reviews
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5 out of 55 out of 55 out of 55 out of 55 out of 5 Swiss Army Knife, 1.18.2012
Reviewer: Mark Torre (Roanoke, VA)

As is, this bike is pretty amazing, but with a few easy changes, the bike can fill multiple roles. Gear it down, swap out the battery & foot pegs, lose the mirrors & the 1lb 5oz cannister, and you'll have a serious off-road machine. Take the weight loss a little further (maybe remove the signals and headlight)and change out the tires, and you've got a very capable racing machine. (at 40+mpg you could go 1/2 gal lighter on gas and shave another 3lbs if the race is less than 50mi) The lightened crank and piston have dramatically improved the agility, and have also made it more rev responsive. The only drawback to this bike is the tall stock gearing and the weight, the latter of which is a trade-off for the "street legal" title. The XCW would be the better starting point if racing was your number one objective, but if the idea of riding to your ride appeals to you this bike is perfect.