Two consecutive hours of pounding through the woods and bouncing off trees is brutal on an ATV's chassis. This severe abuse is unavoidable in a cross-country race, and without adequate protection the results can be absolutely devastating. Like Yamaha with its GYTR products and Polaris with its Pure Polaris components, KTM offers enough armor to protect the XC from a SCUD missile attack. An aggressive aluminum front bumper with a black powdercoat finish gives the 450 an intimidating appearance and doubles as a plow when the competition or underbrush gets in the way. Nerf bars are also available but are not required in cross-country racing. However, they do come highly recommended and prevent entanglement with other machines or trees with intentions of bending your axle. It's not just the cool looks and ability to prevent serious leg injuries that persuade us to bolt on a set. Aluminum skids complete our protection package and are must-have items if you plan to make it through the race season. A quarter ton of adrenaline hurdling through brutal terrain takes a toll on the underside of an ATV and can spell disaster for the unprepared. The aluminum easily resists damage caused by stumps, rocks and unsuspecting magazine cameramen who wander too close to the track. They also create a sled effect allowing the quad to maintain momentum through deep ruts and over obstacles. A few added pounds of alloy are a small sacrifice to make and are worth their weight in gold when a championship is on the line.
While the big rocks are hammering the belly of the machine, their little brothers are being roosted at the rider. This is where proper safety apparel comes into play, but this article is about building a woods racer, so we'll save the safety lecture for another day. Hand guards, on the other hand, are a valid subject. They can deflect knuckle-busting debris and prevent menacing mud from building up on the grips and controls. PowerMadd's hand guards require minimal bar space for mounting and give our XC a sleek appearance. These can't be fully appreciated until you're ripping down a trail bumper to bumper with a rival who is pinned and trying to give you the slip.
Bulletproof armor and the best suspension money can buy mean absolutely nothing if you're racing on a flat tire two miles into a 10-mile course. The stock four-ply tires are great for aggressive trail riding and could possibly make it through their life span without ever seeing a tire repair kit. I, unfortunately, have a well-earned destructive reputation, and taking a chance with a stock tire isn't a risk I'm willing to take. Before making a mad dash for the holeshot award, a new set of AMS Pactrax meats were mounted. We stuck with the same 21-inch front and 20-inch rear tire sizes but opted for a much more durable six-ply design. The two additional layers of rubber offer a significant ability to resist puncture and sidewall damage. Now we can concentrate on putting the power to the ground without the fear of having to limp back into the pit for a tire change.
Now that this machine has the handling to accommodate additional power, the time has come to open it up and get the air flowing. A high-flow exhaust will do the trick without jeopardizing reliability. This stage of the XC project is an easy task since I have the masters of performance at Yoshimura on speed dial. We took their advice and installed the RS-2 full system that is constructed of both stainless steel and aluminum. The installation was a trouble-free undertaking, and after fine-tuning the jetting it was time to hear the XC roar. From the moment the 450 fires an aggressive growl assures any unsuspecting passersby that this is no ordinary 450. The new deep bark can be intimidating, but it's not until you're slamming through the gears that the impact of the RS-2 is evident. Let me assure you that this beast isn't all bark and does have a really nasty bite.