2016 KTM 500 EXC Six Days

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500 EXC

In a Class of It's Own and Unrivalled

The 500 EXC is one of the most powerful standard production Enduro racing machines available on the market. The combination of light weight and high-capacity, high-tech, SOHC 4-stroke technology is the right choice for all those seeking maximum, yet controllable 4-stroke performance. Combined with playful handling, this powerhouse is regarded without doubt as the benchmark in its class.

Slim ergonomics for perfect control

  • Bodywork: The KTM 500 EXC Six Days has bodywork with extremely slim ergonomics and excellent contact points between rider and machine. It provides unlimited freedom of movement.
  • Handlebar: All EXC models are fitted with the super strong, tapered Neken handlebars made of high tensile strength aluminum alloy. The proven standard KTM mount allows the handlebar to be fixed in four different positions. A new light switch made by Leonelli is designed to fulfil the requirements of Enduro use. The open hand guards are serial equipment providing optimum protection of the rider’s hands.

Superior Chassis

  • Individual suspension setting: Each EXC model has its own individual suspension settings, optimally tuned to weight and engine. At the rear, a PDS shock absorber from WP Suspension works with a direct linkage to the upper side of the swingarm. The wide range of setting options for rebound damping and high- and low-speed compression damping are standard on KTM bikes.
  • Telescopic Fork: The KTM Six Days models are equipped with a 48 mm 4CS closed-cartridge fork from WP Suspension. The 4-chamber technology (4CS) patented by WP not only provides a key benefit in terms of responsiveness and consistent damping characteristics, it is also lighter and oil services prove to be far simpler than on the conventional closed-cartridge versions. Naturally, the setting can easily be adapted to track and rider in a matter of a few clicks at the top of the fork: compression damping on the left-hand shaft, rebound damping on the right - another advantage of the 4CS technology.
  • Frame: The modern frame design of the 500 EXC Six Days, comprising lightweight, high strength, chrome-molybdenum steel section tubes, combines maximum longitudinal stiffness with optimum torsional stiffness. It guarantees easy handling and precise steering behavior, as well as excellent ride stability. So the new frame not only shines with the new color, it also clearly represents the benchmark in terms of weight and stability. The frame color shines in the same orange as the KTM factory racing team, making the styling even more attractive. Thanks to the frame design and in conjunction with the rear PDS damping system, impacts at the rear wheel are absorbed and dissipated optimally. For MY 2016 the frame is protected by a robust frame guard.
  • Swingarm: The cast aluminum swingarm has been developed with state-of-the-art calculation and simulation software and constructed, in terms of design and wall thickness, for minimum weight with optimum stiffness and precisely defined flexibility.
  • Brakes: High-tech Brembo brakes have always been standard equipment on KTM offroad bikes, and combined with the lightweight Wave discs, they are the ultimate solution in braking technology. Being the class-leading brakes in Enduro, they are unchanged for MY 2016.
  • High Quality Wheels: The high quality, alloy wheels from GIANT made of extremely stable 7050 aluminum, featuring exclusive Six Days lettering and CNC-machined hubs, are standard on all KTM Six Days models. Developed in cooperation with KTM, the Metzeler tyres provide excellent traction, very precise directional control and a long service life. An additional Six Days standard feature: the Supersprox 2-piece rear sprocket with steel outer ring and aluminum star.
  • Triple Clamp: The high-end CNC machined triple clamps have been specifically designed for enduro use and ensure precise handling thanks to their supporting of the fork flex. The rider receives precise feedback from the front wheel, even in the toughest terrain, thereby increasing riding safety and speed.

The Powerhouse

  • Transmission: The proven 6-speed gearbox is distinguished by easy and precise shifting.
  • Starter: The 500 EXC is equipped with kick-starters as well as 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.
  • DDS Clutch: The single-piece basket of the DDS clutch (damped diaphragm steel) is machined from solid high-tensile steel in one piece 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 its 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 good traction. Finally, the hydraulic clutch mechanism by Brembo in conjunction with the diaphragm spring provides a very light operation and good controllable modulation of the clutch.
  • Engine Management System: The Engine Management System by Keihin with electronic fuel injection and a 42mm throttle body ensures a spontaneous response and maximum engine performance. An oil-cooled 196 W AC alternator provides sufficient energy for the fuel injection, lighting and other electrical loads. With an optional map-select switch from the Power Parts program, the EMS can allow the rider to select different engine characteristics. In addition, the optional User-Setting-Tool provides the facility to readout engine data with a laptop and change the ignition and injection mappings with a few mouse clicks.
  • Engine: Developed for tough Enduro duty, the SOHC engine wtih 510.4cc is distinguished by an extremely compact design, easy maintenance and excellent durability at a minimal weight. Together with the Keihin EFI system, this provides unrivalled Enduro specific performance and rideability.
  • Counter Balancer: In order to balance the mass-forces, the engine uses a counter balance shaft, which doubles as a water pump drive.
  • Crankshaft: The crankshafts with strokes of 72.0mm and ultra-lightweight conrods are made by Pankl from special high-tensile strength steel. The crankshaft employs a plain big end bearing. 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.
  • 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 leads to low friction for improved performance as well as low engine braking action.

General Information

Manufacturer KTM
Model Year 2016
Model 500 EXC Six Days
Model Code 500EXC
Color Six Days

Brakes/Wheels/Tires

Brakes

Front: 260mm Disc

Rear Brake: 220mm Disc

Dimensions

Weight 111.5 kg
Ground Clearance 345 mm
Wheelbase 1,482±10 mm
Seat Height 970 mm

Drivetrain

Transmission 6-Speed
Final Drive 14:50

Engine

Engine 1-cylinder 4-stroke engine
Displacement 510.4 cm³
Bore x Stroke 95 mm x 72 mm
Fuel System Keihin EMS
Fuel Capacity 9 l Unleaded premium fuel (95 RON)
Ignition Contactless, controlled, fully electronic ignition system with digital ignition timing adjustment
Clutch Wet multi-disc clutch DDS / Brembo hydraulics
Cooling Liquid cooling system, continuous circulation of cooling liquid with water pump
Lubrication Forced oil lubrication with 2 Eaton pumps

Operational

Starting Electric starter/Kickstarter
Primary Drive 32:76
Frame Chrome-molybdenum steel central-tube frame
Suspension

WP USD Ø 48 mm 4CS closed cartridge

WP PDS shock absorber