The KTM 500 EXC incorporates the enduro pedigree of the off-road only XC-W line with running gear for the street to create a dual sport like no other. Powered by a 510.4cc SOHC engine, the EXC makes short work of the pavement without fatigue. And when the street ends and the trail begins, it just gets better with playful handling and balanced suspension. For 2016 this dual sport gets the same updates as the dirt-only XC-W models for even better performance, handling and reliability. Riding the 500 EXC means you don’t have to compromise off-road prowess for street capability; you can have your cake and eat it too.
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Bodywork
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Bodywork
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.
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 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.
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Handlebar
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.
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 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.
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 Fuel tank
All fuel tanks are made of lightweight polyethene. 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.
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 Graphics
New graphics with clear lines visually underscore the exacting standards of what KTM deems a true, cutting-edge off-road dual sport bike.
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Superior chassis
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 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.
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 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.
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 Suspension
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.
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 Triple clamps
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.
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 Cooling system
The proven integrated KTM cooling system routes the coolant from the cylinder head through the frame triangle directly to the aluminum radiators made by WP. A radiator fan is standard equipment for the big displacement 500 EXC.
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The powerhouse
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 Transmission
The proven 6-speed gear box is distinguished by easy and precise shifting.
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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.
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 Piston
The lightweight, forged bridged box-type piston shares its high performance piston rings with the 450 SX-F.
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 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.
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 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.
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 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.
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 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.
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 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.
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 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.
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Wheels and brakes
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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.
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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.
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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.
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 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.
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