26/03/2010
KTM 400 EXC: A Trail Riding Masterpiece
When it comes to off-road motorcycles, few names command as much respect and admiration as KTM. Within their esteemed lineup, the 400 EXC has carved out a special niche, celebrated by riders for its potent yet manageable power delivery and its remarkable ability to conquer challenging terrain. This isn't just another dirt bike; it's a tool honed for effortless trail miles, a machine that allows riders to focus on the joy of the ride rather than fighting the machine. Legendary rider Malcolm Smith, a man who has seen the evolution of motorcycling firsthand, has found himself coming full circle, returning to the four-stroke power of the KTM 400 EXC for his trail adventures.

The particular 400 EXC that caught our attention is a special build, a replica assembled by Dave Simon of Scary Fast. This bike is more than just a personal project; it's destined for a greater purpose. Simon is donating the meticulously prepared machine to the Malcolm Smith Motorsports Foundation. This non-profit organisation plans to auction the bike on eBay in July, with all proceeds directly benefiting the El Oasis Orphanage in Valle de Trinidad, Mexico. This orphanage was famously featured in the film "Dust to Glory," and Malcolm Smith himself assures that every single dollar raised will go directly to supporting the children there. It’s a testament to the bike's appeal and the noble cause it supports.
The Magic of the 400 EXC Engine
While the 400 EXC isn't typically laden with extravagant frills, its true brilliance lies in its thoughtfully implemented modifications designed to enhance its trail performance. The engine, the heart of any motorcycle, is where many of these enhancements are focused. This specific machine benefits from the addition of "Power Nows" on both sides of the carburettor, a modification known to improve throttle response and low-end grunt. Complementing this is an FMF Q2 exhaust system, which not only optimises exhaust flow for better performance but also contributes to a more refined sound. These upgrades transform the already capable 400 EXC engine into something truly special.
Malcolm Smith's riding often takes him through the demanding rocky terrain of Colorado. To meet these challenges, the bike features a custom suspension setup from Slavens, a Colorado-based specialist. The goal was to achieve a level and balanced ride, and the results are impressive. The 400 EXC, with this tailored suspension, “soaks up rocks and chop well.” Crucially, the rear end is described as being “very controlled,” eschewing the loose feeling that can plague some plush KTM rear shock setups. While it handles whoops competently, its design is clearly aimed at the nuanced demands of trail riding rather than outright high-speed desert racing. The engine's character is consistently praised as "magic on the trail," offering "smooth, controllable but energetic power." It’s this blend of user-friendliness and spirited performance that makes the 400 EXC so addictive.
The stock 400 EXC is already well-regarded for its smooth power delivery and free-revving nature. However, the modifications on this particular bike amplify these traits, providing “more zip and energy from right off idle to all the way through the rpm range.” The sensation is one of constant forward momentum, where “every revolution of the crank generates trail speed.” Wheelspin, a common adversary on the trails, is “almost nonexistent” on this finely tuned machine. Malcolm typically opts for a 13-tooth countershaft sprocket for added low-end tractability. However, with the FMF exhaust and Power Nows installed, he found the stock 14-tooth sprocket to be perfectly adequate, highlighting the effectiveness of the engine modifications. The only minor quibble noted is a desire for a lower first gear, a common wish for technical trail riding.

Comfort and Control: Effortless Trail Miles
The KTM 400 EXC truly excels when it comes to providing “effortless trail miles.” This is particularly evident when compared to its larger-displacement stablemate, the 525. The 400 EXC offers a level of comfort that significantly reduces rider fatigue, allowing for longer, more enjoyable rides. The inclusion of a Scotts steering damper is a game-changer for trail riding. With the damper in place, the rider experiences a notable reduction in headshake and a greater sense of stability, meaning there's “no need to hold onto the bar tightly.” This allows the rider to maintain a more relaxed posture, conserving energy and improving control. The overall feeling is one of confidence, with the bike feeling “ready for anything” the trail throws at it.
The reduction in physical demand is remarkable. It's suggested that there might not have been a four-stroke motorcycle before that is “less physically demanding.” This allows the rider to channel all their available energy into the more enjoyable aspects of off-road riding: “picking lines and smiling like Malcolm Smith.” That infectious grin Malcolm is known for? It’s easy to understand why when you’re aboard a machine that makes trail riding this rewarding and accessible.
KTM 400 EXC Racing (2005) Specifications
For those interested in the technical details of this capable machine, the 2005 KTM 400 EXC Racing offers a compelling package. KTM themselves describe it as the “all-rounder in the KTM off-road program,” boasting a “broad power band, great top-end performance and optimal traction.” It’s even noted as being the “most sought-after motorcycle on the KTM Adventure tours,” underscoring its versatility.
| Model Name | KTM 400 EXC Racing |
| Year Model | 2005 |
| Type | Cross / Motocross |
| Engine Size | 398.2 cc (24.30 cubic inches) |
| Type of Engine | Single cylinder, four-stroke |
| Compression | 11.0:1 |
| Bore x Stroke | 89.0 x 64.0 mm (3.5 x 2.5 inches) |
| Valves per cylinder | 4 |
| Fuel system | Carburettor. Keihin MX FCR 39 |
| Fuel control | Overhead Cams (OHC) |
| Ignition | Kokusan digital 4K-3B |
| Lubrication system | Pressure lubrication with 2 Eaton pumps |
| Cooling system | Liquid |
| Gearbox | 6-speed |
| Transmission type | Chain (final drive) |
| Clutch | Wet multi-disc clutch, operated hydraulically |
| Frame type | Chromium molybdenum |
| Rake (fork angle) | 26.5° |
| Trail | 112 mm (4.4 inches) |
| Front suspension | WP-USD 48 mm |
| Rear suspension | WP-PDS-shock absorber |
| Rear wheel travel | 335 mm (13.2 inches) |
| Front brakes | Single disc |
| Front brake diameter | 216 mm (8.5 inches) |
| Rear brakes | Single disc |
| Rear brake diameter | 260 mm (10.2 inches) |
| Dry weight | 113.5 kg (250.2 pounds) |
| Seat height | 925 mm (36.4 inches) |
| Ground clearance | 380 mm (15.0 inches) |
| Wheelbase | 1481 mm (58.3 inches) |
| Fuel capacity | 8.00 litres (2.11 US gallons) |
| Starter | Electric & kick |
Frequently Asked Questions
Q: What makes the KTM 400 EXC so good for trail riding?
A: Its engine offers a perfect balance of smooth, controllable power with enough energy for spirited riding. Combined with a comfortable chassis and effective suspension, it significantly reduces rider fatigue, making long trail rides enjoyable.
Q: What kind of modifications were made to Malcolm Smith's 400 EXC?
A: The bike featured "Power Nows" for improved throttle response, an FMF Q2 exhaust for better performance and sound, and a custom suspension setup from Slavens for enhanced handling and control on rocky terrain. A Scotts steering damper was also added for stability.

Q: What is the significance of this particular 400 EXC being auctioned?
A: The bike is being donated by Dave Simon to the Malcolm Smith Motorsports Foundation to be auctioned on eBay. All proceeds will go to the El Oasis Orphanage in Mexico, supporting the children there.
Q: How does the 400 EXC compare to larger displacement KTM models for trail riding?
As noted, the 400 EXC is considered less physically demanding, contributing to more effortless trail miles and reduced rider fatigue compared to larger bikes like the 525.
Q: What are the brake sizes on the 2005 KTM 400 EXC Racing?
The 2005 KTM 400 EXC Racing features a 216 mm (8.5 inches) front disc brake and a 260 mm (10.2 inches) rear disc brake.
The Enduring Appeal of the 400 EXC
The KTM 400 EXC isn't just a motorcycle; it's an experience. It represents a sweet spot in the off-road spectrum, offering a potent and engaging ride without the overwhelming power that can intimidate less experienced riders or lead to premature fatigue. Its reputation as a versatile and capable machine is well-earned, making it a favoured choice for adventure tours and demanding trail rides alike. The story of Malcolm Smith embracing this model, and the charitable endeavour surrounding this particular replica, further cements the 400 EXC's status as an off-road legend. It’s a bike that allows you to truly immerse yourself in the ride, leaving you with nothing but the thrill of the trail and, perhaps, a grin as wide as Malcolm Smith's.
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