2016 KTM 500 EXC


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Fun Center-Durango
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500 EXC



The 450 and 500 EXC models are undisputedly the most powerful Enduro machines of their classes. Combining low weight and high displacement, high-tech SOHC (single overhead camshaft) 4-stroke technology is the right choice for all riders that are looking for maximum four-stroke performance, combined with playful handling for the E2 and E3 classes. These power-houses are without a doubt the benchmarks in their classes.

  • Airbox: The air filter can be quickly replaced without the use of any tools, thanks to an ingenious airbox design guarantees optimum filter protection from flying dirt while creating maximum airflow for high performance. The airbox covers are manufactured in a 2-component process with in-mold graphics. In addition, two extra flaps on the left cover allow it to be secured with bolts if desired.
  • Speedo: The speedometer by MAE integrates all the warning and indicator lights, except the turn signals, in a single unit. This gives the cockpit a clean and minimal look, with clear and readily available information.
  • Graphics: New graphics with clear lines visually underscore the exacting standards of what KTM deems a true, cutting-edge off-road dual sport bike.
  • Fuel tank: All fuel tanks are made of lightweight polyethylene. These large capacity tanks are specifically designed for Enduro use and have a release mechanism of the ¼-turn bayonet filler cap that can be opened quickly and easily.
Superior Chassis
  • Frame: The EXC's chassis is second to none and for 2016 the bikes will feature the striking Factory orange usually seen only on KTM's race team machines. The modern and lightweight frame design with exceptional quality and performance created by WP Performance Systems is made of lightweight, high strength chromoly steel sections. Not only does it provide easy handling and precise cornering, but also outstanding stability.
  • Swingarm: The cast aluminum swingarm has been developed with state-of-the-art calculation and simulation software and constructed for minimum weight, optimum stiffness and precisely defined flexibility.
  • Suspension/damping: The EXC models feature WP suspension, which is specifically designed for dual sport riding and ensures maximum traction comprised with plenty of comfort. As expected, the compression and rebound damping can be adjusted to suit various conditions and rider preference as well as separate high and low speed shock compression adjustments.
  • Cooling system: The proven integrated KTM cooling system routes the coolant from the cylinder head through the frame triangle directly to the aluminium radiators made by WP. A radiator fan is standard equipment for the big displacement 500 EXC.
The Powerhouse
  • Transmission: The proven 6-speed gear box is distinguished by easy and precise shifting.
  • Starter: The 500 EXC is equipped with a kickstarter as well as an electric starter as standard. The electric starter is well protected behind the cylinder.
  • Piston: The lightweight, forged bridged box-type piston shares its high performance piston rings with the 450 SX-F.
  • Engine management system: The Engine Management System by Keihin with electronic fuel injection and a 42mm throttle body delivers a spontaneous response and maximum engine performance. An oil-cooled 196W AC alternator provides sufficient energy for the fuel injection, lighting and other electrical loads.
  • Engine: Developed for dual sport, the SOHC engine with 510.4cc is distinguished by an extremely compact design, easy maintenance and excellent durability at a minimal weight. Together with the Keihin EFI system, the 500 EXC provides unrivaled enduro-specific performance and rideability.
  • DDS clutch: The one-piece basket of the DDS clutch (damped diaphragm steel) is machined from solid high-tensile steel in one solid part together with the primary drive gear. This process guarantees unbeatable reliability and, together with the thin steel linings, contributes to the narrow engine width due to a compact rivet-less design. The diaphragm spring makes it possible to implement an additional rubber damping system inside the clutch hub, ensuring reliability for the transmission and excellent traction. Finally, the hydraulic clutch mechanism by Brembo in conjunction with the diaphragm spring provides a very light clutch operation and controllable modulation.
  • Cylinder head: The cylinder head is equipped with a single overhead camshaft. It activates two titanium intake valves and two steel exhaust valves. The weight optimized valve train has low friction for improved performance as well as low engine braking action.
  • Crankshaft: The crankshaft and ultra-lightweight connecting rod are made by Pankl from special high-tensile strength steel. The crankshaft employs a plain big end bearing, and two force-fitted bearing shells run directly on the crank pin. The necessary oil feed for this bearing is ensured by the engine's pressure lubrication. This design increases the engine's long-term durability, and lengthens crankshaft service intervals, which is a customer benefit in terms of time, effort and cost.
  • Counter balancer: In order to balance the mass-forces, the engine uses a compact counter balance shaft, which doubles up as a water pump drive.
Wheels and Brakes
  • Wheels: The EXC's feature new high-quality black anodized Giant rims with black spokes, that are mated to CNC-machined hubs and lightweight silver aluminum nipples for maximum stability at minimum weight. The EXC's feature Metzler Six Day DOT tires.
  • Brakes: High-Tech Brembo brakes have always been standard equipment on KTM off-road bikes, and combined with the lightweight Galfer Wave discs, they are the ultimate solution in braking technology. Being the class-leading brakes in off-road, they remain unchanged for 2016.
  • Front axle: The front axle has been reduced in size from 26mm to 22mm to reduce weight and offer better front end feel. The adjusted offset and increased trail provides more stability.
  • Front fork guards: The fork protectors have been adapted to the fork shoes and are also lighter. The open design offers the same level of protection while giving easier access to the fork legs for quicker cleaning and faster maintenance.
  • Design: 1-cylinder, 4-stroke engine
  • Displacement: 510.4 cm³
  • Bore: 95 mm
  • Stroke: 72 mm
  • Starter: Kick and electric starter
  • Transmission: 6-speed
  • Primary drive: 32:76
  • Secondary gear ratio: 14:50
  • Clutch: Wet, DDS multi-disc clutch, Brembo hydraulics
  • EMS: Keihin EMS
  • Frame design: Chrome-molybdenum steel central-tube frame
  • Front suspension: WP USD Ø 48 mm
  • Rear suspension: WP PDS shock absorber
  • Suspension travel (front): 300 mm
  • Suspension travel (rear): 335 mm
  • 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 deg.
  • Wheelbase: 1482 ± 10 mm
  • Ground clearance: 345 mm
  • Seat height: 970 mm
  • Tank capacity (approx.): 9 L
  • Weight READY TO RACE (without fuel): 111.5 kg



Engine Type
1-cylinder, 4-stroke engine
510.4 cc
Bore and Stroke
95 x 72 mm


Front Suspension
WP USD Ø 48 mm
Rear Suspension
WP PDS shock absorber
Front Brakes
Disc brake
Rear Brakes
Disc brake


1482 ± 10 mm
Seat Height
970 mm
Fuel Capacity
9 L
Dry Weight
Curb Weight: 111.5 kg