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2012 KTM 450 EXC Review

450 EXC: THE BENCHMARK

The 450 EXC can justifiably claim to be the most widely ridden bike in enduro sport and a serial winner in the E2 World Championship. The top dog has been revamped and slimmed down in practically every aspect - from the frame to the electronic injection and the engine management system to the material selection. Above all, the new chassis and redesigned OHC engine widen the 450 EXCs lead over the competition by a further bike length. Extremely light, supremely agile and endless power - thats what winners look like.

With the 450 EXC there isn’t a terrain or terra firma it can’t tackle. When the dirt ends, there’s no better solution than a street-legal EXC. Trails connected by pavement, no problem. Trails filled with different passages, rocks and slippery logs and roots, no problem. Street legal has never been so versatile and fun.

2012 KTM 450 EXC Features and Benefits

NOW EVEN MORE ERGONOMIC

BODYWORK

The 450 EXCs new bodywork with the very slim seat and spoiler lines, plus excellent contact points, perfects the bikes ergonomics, making handling even simpler and more precise. The longer rear fender protects the rider even more effectively from swirled up stones.

NOW WITH EVEN MORE PERFORMANCE

NEW ENGINE

With the 450 EXCs 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.

NEW EFI/EMS

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.

NEW OIL CIRCUIT

The 450 EXCs 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.

NEW BALANCER SHAFT

The 450 EXCs new, laterally integrated 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 450 EXCs new engine.

NEW ENGINE CASE

The 450 EXCs 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.

NEW CRANKSHAFT

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.

NEW CYLINDER AND PISTON

The 450 EXCs 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.

NEW CYLINDER HEAD

All ports and the combustion chamber have been redesigned in the OHC cylinder head of the 450 EXCs new engine. The new camshaft actuates four valves via lightweight rocker arms, with high-quality titanium valves being used on the intake side.

NEW CLUTCH

The 450 EXCs 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 Brembo® facilitates sensitive modulation of the clutch.

NEW SILENCER

The 450 EXCs new, improved silencer not only offers greater volume and a new design, it also reduces noise levels to the stricter standards of the future.

NOW WITH AN EVEN MORE SUPERIOR CHASSIS

NEW FRAME

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 450 EXC have been further optimised.

NEW SWINGARM, NEW PDS, NEW SETTING

The 450 EXCs 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.

TELESCOPIC FORK, NEW SETTING

The 450 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 450 EXCs simple handling and precision.

NEW WHEELS

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 450 EXC.

International Specifications/Technical Details
Europe MSRP Price: 6,995.00 GBP*

Engine
Engine type Single cylinder, 4-stroke
Displacement 449.3 cc
Bore/stroke 95/63.4 mm
Compression ratio 11,8:1
Starter/battery Kick- and electric starter / 12V 4Ah
Transmission 6 gears
Carburetor Keihin EFI, flow restrictor 42 mm
Control 4 V / OHC with rocker levers
Lubrication Pressure lubrication with 2 oil pumps
Gear ratios 14:36 17:32 19:28 22:26 24:23 26:21
Primary ratio 32:76
Final drive 14:52 (13:52)
Cooling Liquid cooling
Clutch Wet multi-disc clutch, Brembo hydraulics
Ignition Keihin EMS

Chassis
Frame Central double-cradle-type 25CrMo4
Subframe Aluminium
Handlebar Neken, Aluminium Ø 28/22 mm
Front suspension WP-USD Ø 48 mm
Rear suspension WP-PDS shock absorber
Suspension travel front/rear 300/335 mm
Front/rear brakes Disc brake Ø 260/220 mm
Front/rear rims 1.60 x 21; 2.15 x 18 Excel
Front/rear tires 90/90-21; 140/80-18
Chain X-Ring 5/8 x 1/4"
Silencer Aluminium
Steering head angle 63.5°
Wheel base 1,482±10 mm
Ground clearance 345 mm
Seat height 970 mm
Tank capacity, approx. 9.5 l
Weight, without fuel, approx. 111 kg

* Manufacturers suggested retail price (MSRP), the actual sale prices can vary.

American and Canadian Specifications
US MSRP Price: See KTM dealer for pricing.

ENGINE
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 449.3 cm³ (27.418 cu in)
Bore 95 mm (3.74 in)
Stroke 63.4 mm (2.496 in)
Starter Electric starter/kick starter
Engine lubrication Pressure circulation lubrication with 2 rotor pumps (engine) / 1 rotor pump (transmission)
Primary transmission 33:76
Final drive 15:45
Cooling Water, permanent circulation of coolant by water pump
Clutch Multidisc clutch in oil bath / hydraulically activated
Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan

CHASSIS
Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP Suspension Up Side Down 4860 MXMA PA
Shock absorber WP Suspension PDS 5018 DCC
Suspension travel Front 300 mm (11.81 in)
Suspension travel Rear 335 mm (13.19 in)
Brake system Disc brakes, brake calipers on floating bearings
Brake discs - diameter Front 260 mm (10.24 in)
Brake discs - diameter Rear 220 mm (8.66 in)
Chain 5/8 x 1/4"
Steering head angle 63.5°
Wheelbase 1,475±10 mm (58.07±0.39 in)
Ground clearance unloaded 380 mm (14.96 in)
Seat height unloaded 985 mm (38.78 in)
Total fuel tank capacity, approx. 9.2 l (2.43 US gal)
Super unleaded (ROZ 95/RON 95/PON 91)
Weight without fuel, approx. 114.8 kg (253.1 lb.)