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The Ultimate 2020-23 KTM 500 EXCF / XCFW - Husky FE / FE-S Bike Build

A guide to building a great 2020-23 KTM 500 EXCF / XCFW or Husqvarna FE / FE-S. Instead of just re-selling the same old things everyone else sells, these are products that fix the specific issues these bikes have. When you compare them to anything else, for sound, power, protection and rideability, nothing can compare for even close to these prices.

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Please note, that the 2020,21,22 and now 2023 bikes are the same.  The XCFW and FE offroad models, have the same power robbing issues that the street versions do. They just have a slightly more open exhaust and a traction control / map switch. The map switch just changes ignition timing a bit.    All versions need the our ECU Reprogramming service, to be able to run right

If you’re like us (and most others who recently spent a lot on a new KTM or Husky) you probably thought your new bike was just going to run perfectly all the time with no problems...Boy did we get suckered!

 

Based on our experience, here’s what you’re most likely finding:

  • The bike feels really plugged up due to the intake and exhaust restrictions.

  • Your bike runs lean in fuel.

  • Your bike and exhaust are getting excessively hot when riding.

  • The throttle is less responsive than you expected.

  • The bike likes to flame out and stall.

The good news is, all this stuff is really easy to fix, and it doesn't cost a lot.   The bad news is, you can't just do one or two things like the old days.  You have to commit to all four steps, or don't start and just live with the issues.

The good news one more time is, you can fix all the issues, plus get the kind of power you see below, for a measly 

 

 

 

20hp gain on 500 KTM Performance Power Bundle.jpg

*For testing, the rear tire was replaced with a street tire, and was ran with 100% wide open throttle.

The bottom line above shows the power  numbers from a stock 2022 500 EXC-F at wide open throttle in 5 th gear. It’s making about 42 horsepower stock.

The top line is how much power you can get out of the bike with our kits.  Up top it's a  20.2 hp gain.  There has never been anything like this kit.       Plus, it fixes all the other problems with the heat and stalling.

      Plus, it's the only kit on the market , that has a 30 day satisfaction guarantee.   It can't be beat by anyone

The "overall" power gain, you see here, is the same with either of the 2 power bundles.   The lower priced bundle for $560 and the higher priced bundle for $780, make the same overall power gain you see here.

The difference between the 2 is the $780 one has more bottom end response and pull, due to the exhaust manifold.  It also has no chance of fuel line parts breakage or fuel filter clogging.  The stock fuel parts are plastic and can split and leave you stranded.  The stock fuel filter is extremely small, so it can clog easily and give you the sputters and hesitations.

That's why you get 7 or so of the little replacement elements in. your tool kit, when you buy the bike.  KTM just knows you are going to have to stop in the middle of nowhere and change it, when the bike starts to act odd.   Our big filter ensures you never need to do this

If you want to make the smart decision and start with POWER BUNDLE or ULTIMATE POWER BUNDLE, 

Just know that you will either need to : 

1.  Send your ECU in and have it reprogrammed. ( About 7 days of down time overall )

2.  Buy one of our pre built ECU's and then send yours back in for the core refund.  Call or email to see if we have one at the       time and if so, then there is no down time with this.

3.  Or just buy and finished ECU outright, if we happen to have one.  Call or email for this option to get the best price at the         time

If you choose to just go the POWER BUNDLE route, you will solve these problems

1.  You will run cool and the exhaust won't burn your leg.

2. The fan won't be on all the time

3. The bike will no longer stall or flame out

4. The vibration will be reduced

5. You will be able to remove the reed assembly from the intake tract, so the reeds to break off, stick between your valves and cylinder headend destroy your engine.

6. You will gain power starting right from idle and ending at 20 HP more than stock.

7. You won't be mad at yourself for spending 3 - 4 times the amount of money, for lesser results

     The reason these changes need to be made, is because of the restrictions that had to me made, to make them sellable as street legal.  And if they are street legal, they can be ridden year round, in all 50 states.  Problem is, the restrictions are pretty detrimental to the health of the engine, and maybe the health of the rider. 

Big problem is, you can't just change one of the restrictions, without causing adverse reactions to the needed fuel. 

Here are your Minimum to Maximum steps to improvement.  

1.  If you just feel you need to add fuel to the bike, then no problem.  You can do that for a measly $29.95.   All you nee is our Oxygen sensor, or O2 sensor delete dongle.   You unplug the stock 02 sensor from the wiring harness, and plug this dongle in to the harness.

      It will richen your bike from an air fuel ratio of 14.7 :1, to and AFR of 13.5 or so.    The bike will run cooler, start easier, not flame out as much and have better response and power, below 600o rpm or half throttle.

      You will get engine codes with this plug sometimes though, and the bike will still flame out occasionally, until the exhaust end cap is changed. 

Exhaust Power End Cap

The stock exhaust is so restrictive, on all of these bikes, that all that heat and pressure can't get out of the engine.  This causes stalling, that really really restrictive feel and running real hot. This is the biggest reason that your fan is always coming on.
 

So just opening the exhaust up, with our Power end cap with spark arrestor, is the first big gain.Available in satin silver or black

ktm exhaust performance end cap.jpeg
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  If you just feel you need to add fuel to the bike, then no problem.  You can do that for a measly $29.95.   All you nee is our Oxygen sensor, or O2 sensor delete dongle.   You unplug the stock 02 sensor from the wiring harness, and plug this dongle in to the harness.

      It will richen your bike from an air fuel ratio of 14.7 :1, to and AFR of 13.5 or so.    The bike will run cooler, start easier, not flame out as much and have better response and power, below 600o rpm or half throttle.

      You will get engine codes with this plug sometimes though, and the bike will still flame out occasionally, until the exhaust end cap is changed. 

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