2012 KTM 500 EXC as a Lightweight Dual Sport

Discussion in 'Thumpers' started by harcus, Dec 3, 2011.

  1. Zuber

    Zuber Zoob

    Joined:
    Sep 28, 2004
    Oddometer:
    2,606
    Location:
    Main Street, Shedd, Oregon
    Both the emission systems used on the EXC are downstream of the ECU with no feed back.

    The air injector lets more air into the exhaust, essentially a huge exhaust leak that adds to the volume of gas coming out the exhaust. More volume means the percentage of pollutants coming out the exhaust is lower. But, you still get the same amount of pollutants weather this this device is hooked up or not.

    The charcoal canister and gas tank capture system actually reduce the VOC being put into the air. It captures the fumes coming off the gas tank (and off the carb on the 530's) and burns them in the engine. If you keep the bike upright, never overfill the tank and never park it in the sun when full, then this system will work OK. But, once raw fuel goes out the overflow pipe and gets trapped in this system, your engine will run erratically and may not run at all after a tip over. On the BMW's it would even lock up the motor. The ECU controls the venting from the charcoal canister into the intake with an electrical solenoid. The ECU does not know if this solenoid is even connected or not, there is no feedback. This system allows a little air to leak past the throttle body all the time, which makes the idle slightly higher. When you pull this system, you lower the air leak and need to make it up by raising the idle. The ECU can't tell where the air is coming from, through the TB or leaking in from the Evap system.

    The EXC and XC-W's have different MAP's, but they are very similar and labeled 'California Green Sticker' compliant. These are 'restricted' maps, they don't respond to the different MAP plugs, they don't allow modification with the User Setting Tool. You can replace the MAP's now with the un-restricted ones for 'off-road use only' or Australia, which is way, way off road.

    On a slightly different topic, KTM just got its pee-pee slapped and will no longer sell after-market slip-on mufflers for street legal bikes. They were a good source for Acropovitch and FMF exhaust systems, but the Fed's noticed this and shut them down. I think this was mostly due to the latest Kalifornia code about only allowing stock mufflers on 2013 bikes.
  2. harcus

    harcus Long timer

    Joined:
    Feb 27, 2005
    Oddometer:
    1,337
    Location:
    Edge of the Wasatch
    It's about time! :D

    And BTW... You will find that this is the bike you were wanting all along! I can hear you smiling now...:D
  3. harcus

    harcus Long timer

    Joined:
    Feb 27, 2005
    Oddometer:
    1,337
    Location:
    Edge of the Wasatch
    By approx 16% from experience...

    Original mileage = 66 mpg
    JD Tuner mileage = 55 mpg

    And it seems to run smother at all RPMs = good!

    :D
  4. harcus

    harcus Long timer

    Joined:
    Feb 27, 2005
    Oddometer:
    1,337
    Location:
    Edge of the Wasatch

    All quite true with a tweak. I believe that the "injected" air right outside the exhaust port actually burns some of the unburned fuel thus reducing unburned hydrocarbons. Remember the early days of EPA where they were fitting air pumps onto any engine? It improves the air but sadly, no energy is recovered.
  5. tentative_rider

    tentative_rider Wanna Be On Gravel

    Joined:
    Jul 11, 2009
    Oddometer:
    192
    Location:
    Cupertino CA
    ok all -

    I have a 2013 500 EXC. I have already removed the SAS and evap canister, installed the 5.3 gal Acerbis tank (routed the vent hose through leftover hose that is attached to the left frame rail by capping the "T" connection and removed the hose plug).


    Besides the plate carrier, gearing, turn signals and mirrors (already replaced with folding models) -- simply to satisfy my curiosity, what ARE the differences between my 2013 U.S. 500 EXC and a 2013 U.S. 500 XCW?

    I really enjoy riding this bike and do not plan on any changes to the ECU map or exhaust at this time.


    Thanks for your input.
  6. Nice_Rumble

    Nice_Rumble Long timer

    Joined:
    Dec 9, 2004
    Oddometer:
    2,361
    Location:
    New London, NH
    Is it safe to say that the 500 EXC will consistently get 60 plus miles per gallon with a stock machine? Need to cover at least 150 miles between fuel stops.
  7. wsmc831

    wsmc831 Been here awhile

    Joined:
    Jan 25, 2006
    Oddometer:
    879
    Location:
    Central Oregon
    No, it won't do 60 mpg. Figure 100 miles on stock tank, roughly. Plenty of larger tanks....150 range is not a big deal.
  8. harcus

    harcus Long timer

    Joined:
    Feb 27, 2005
    Oddometer:
    1,337
    Location:
    Edge of the Wasatch
    I think it depends on you & the type of riding. I find that off road in the cedars burns more fuel than cross country with a load. I was consistently getting 66 mpg cross country before installing the JD tune box. It now gets 55 mpg consistently cross country & more like 35-40 in the trees. Which, IMHO, is not bad.

    BTW - Running the 3.4 gal / 13L KTM tank. If on a long ride I carry a RotoPax for backup. Originally, I would get 180 ish miles on the 3.4 tank.

    Additionally, I know of others around here that reported similar original performance.

    :D
  9. KrustyKustom

    KrustyKustom Lets Go....

    Joined:
    Dec 9, 2005
    Oddometer:
    668
    Location:
    Desert-away from people...
    In Moab I got 57 mpg for several tanks. Running 13/48. That was with some heavy throttling as well!
  10. PatrickM

    PatrickM Been here awhile

    Joined:
    May 6, 2012
    Oddometer:
    410
    Location:
    Zephyr Cove, NV
    Is the kytech still the rear rack to get? How much weight can that thing hold (e.g. 2-5 gallon rotopax?)
  11. Wonkyconk

    Wonkyconk Adventurer

    Joined:
    Feb 26, 2012
    Oddometer:
    21
    Location:
    Coleford, glos, england
    Hi,
    Can I get some infor on the waterproof soft panniers please?
    Anybody using them, what's your opinions?
    I have wolfman pannier racks on my wr250r will these attach ok?
    I think the 35l litre ones would be best for me.
    Cheers
  12. Nice_Rumble

    Nice_Rumble Long timer

    Joined:
    Dec 9, 2004
    Oddometer:
    2,361
    Location:
    New London, NH
    Do you have a link to the 3.4 gallon KTM tank? How to you carry the Rotopax?
  13. harcus

    harcus Long timer

    Joined:
    Feb 27, 2005
    Oddometer:
    1,337
    Location:
    Edge of the Wasatch
    13 L tank - Go to your dealer or ...

    http://www.ktm-parts.com/7810791324404.html

    >>>>Disclaimer - This is not ment to be an advertisement <<<<<

    RotoPax - I carry the cans on this rack...

    http://www.shop.globetrottin.com/product.sc?productId=61&categoryId=35

    using these plates...

    http://www.shop.globetrottin.com/product.sc?productId=59&categoryId=3

    These come from my shop.

    Many inmates on this site have these so ask around.

    Note - 10 % discount to inmates

    :D
  14. harcus

    harcus Long timer

    Joined:
    Feb 27, 2005
    Oddometer:
    1,337
    Location:
    Edge of the Wasatch
    Not sure if you are referring to the products on our site...Globetrottin.com...

    But if so, yes they fit Wolfman racks as well as ours.



    :D
  15. Nice_Rumble

    Nice_Rumble Long timer

    Joined:
    Dec 9, 2004
    Oddometer:
    2,361
    Location:
    New London, NH
  16. Stu

    Stu Buffo Maximus

    Joined:
    Feb 4, 2004
    Oddometer:
    1,039
    Location:
    Eastern YahooLand
    I tested this rack as much as i could (crashing). Held up great. I carried the 1 gal. Rotopax which in southern Utah was needed for my friends, but not by me with the 3.4 gallon KTM accessory tank. The Globetrottin bags were pretty waterproof as well. Zero complaints. Normally I race my 500 but with these accessories I was ready for long distances and camping.

    Stu
  17. ABYSS

    ABYSS KTM

    Joined:
    Oct 16, 2006
    Oddometer:
    1,198
    I still have that brand-new 13 L tank (new in the box never installed ) :evil if any inmate is interested.
  18. Stu

    Stu Buffo Maximus

    Joined:
    Feb 4, 2004
    Oddometer:
    1,039
    Location:
    Eastern YahooLand
    The 3.4 is worth the money. About $200. You can easily install the fuel pump and lines. The tank should come with the different mounting hardware. If not, contact your dealer to get it. The tank's plastic bosses in the bottom are not as thick as the stock tank. You need different mounting hardware.

    Stu
  19. dieselcruiserhead

    dieselcruiserhead Long timer

    Joined:
    Jul 25, 2008
    Oddometer:
    1,620
    Location:
    Park City, Utah
    I also have Harcus's rack, the ultra light one (5 lbs for the whole rack :evil ). I can't say enought good things about the rack. I then use OR 15 liter drybags which are also completely water proof and the setup is awesome. No drilling required, quickly convert back to dirtbike mode by removing the rack. Killer. I also followed Harcus for 3 days on his 500 with his drybags and they were also completely killer.. Very nice stuff! (and reasonable too, in my opinion)
  20. Nice_Rumble

    Nice_Rumble Long timer

    Joined:
    Dec 9, 2004
    Oddometer:
    2,361
    Location:
    New London, NH
    http://www.shop.globetrottin.com/product.sc?productId=63&categoryId=33

    Is this the rack you are referring to? Where does the aluminum mount attached to the middle cross bar attach?

    [​IMG]

    [​IMG]