When FMF Racing reached out to us asking to collaborate on a 2020 KTM 500 EXC-F build, we couldn’t say yes fast enough. The 500 EXC-F is already an exciting platform, but FMF had some killer ideas on how to take the bike to the next level. With their vision, our parts, and some help from a few other sponsors, we built the 500 EXC-F into an enviable off-road machine.

A Brief Look at the KTM 500 EXC-F

The 500 EXC-F has been around in some form since the late ‘80s, but has seen some serious innovation and upgrades over the last 30-something years. For 2020, the bike actually got a complete overhaul, something that hasn’t happened since 2012. Redesigned and refreshed, the 2020 500 EXC-F is equal parts competitive and innovative with a host of new features:

  • Reworked chassis
  • Updated camshafts, exhaust systems, and electronic fuel injection (EFI)
  • Computational Fluid Dynamics (CDF) technology and a smarter coolant circuit routing to ensure optimum engine temperature in all riding conditions
  • A new two-piece header pipe which can be disassembled much more easily for better access to the shock
  • New high-tech lightweight chromoly steel frames

Riding the Built 500 EXC-F

That list just scratches the surface of this exciting bike in KTM’s celebrated range of 4-strokes. Check out the table below for the full specs of the 2020 KTM 500 EXC-F to see what we were working with on this build.

2020 KTM 500 EXC-F Specs
Displacement 510.9 cm3
Design 1-cylinder, 4-stroke engine
Bore 95 mm
Stroke 72 mm
Starter Electric Starter
Transmission 6-speed
Clutch Wet, DDS multi-disc clutch, Brembo hydraulics
EMS Keihin EMS
Frame Design Central-tube frame with double-cradle
Rear Suspension WP Xplor PDS shock absorber
Front Brake Brembo twin-piston floating calliper, brake disc
Rear Brake Brembo single-piston floating calliper, brake disc
Front Brake Disc Diameter 260 mm
Rear Brake Disc Diameter 220 mm
Chain X-Ring 5/8 x 1/4″
Steering Head Angle 63.5°

The Build

Like we said, FMF already had a few parts in mind to fine-tune the performance of their 500 EXC-F.

The Built Bike on Display


It’s hard to beat Rekluse’s Radius CX Clutch when it comes to off-road riding. An auto clutch, the Radius CX automatically engages and disengages, meaning all you have to do is shift and twist. When you’re navigating through rocks, roots, and rough terrain, it’s nice to have one less thing to worry about.

Rekluse Clutch

To go along with the new clutch, the bike was, of course, outfitted with an FMF Factory 4.1 RCT Exhaust. The full system enhanced the performance, sound, and overall look of the bike.

FMF Exhaust Pipe

Chassis and Drive

Next on the list were some new wheels, so we set the bike up with a set of the Tusk Impact Wheels – black rims, silver spokes, and orange hubs. The Tusk wheels are lightweight, durable, and can even be a few lbs. lighter than most stock wheels. Plus, the wheels can be bought fully assembled or as separates, which means they can be as plug-and-play or customized as you want them to be.

Tusk Impact Wheels

Mounted on the new wheels are Dunlop Geomax EN91 Enduro tires. When it comes to off-road handling and reliability, the EN91s are tough to beat. Their tread pattern offers traction in the loose stuff and high speeds alike, and their tread compound is made to be both strong and durable. Dunlop’s Tilt Crown Blocks (TCB) can be found through the tire as well, working to improve handling, especially on rocky and stone surfaces.

Dunlop Geomax EN91 Enduro

We also equipped the bike with some of our in-house Tusk Typhoon Brake Rotors. Minimalistic and sleek, the rotors are the ideal blend of performance and style.

Off-Road Accessories

If it’s riding off-road, it needs a set of Tusk D-Flex Pro Handguards – it’s as simple as that. Shielding your hands from roost, debris, and even a little bit of the elements, the D-Flex handguards are a great way to up your bike’s protection and give it some color.

Another necessity for FMF’s KTM was an upgraded fuel tank. They opted for the IMS 3.0 Gallon Tank. The natural color looks great, the capacity allows for longer rides, and the increase in size doesn’t look or feel bulky on the bike.

IMS 3.02 Gallon Tank

The Baja Designs XL80 LED Light Kit was another a natural fit for the 500 EXC-F. The setup offers more than the average headlight, boasting 9,500 lumens, a waterproof construction with MoistureBlock ™, and an LED life expectancy of 49,930 hours. Designed to be the optimal mix of power and performance, the XL80 is one of the best headlights on the market for off-road riding.

Baja Designs XL80 LED Light Kit

The apex of FMF’s off-road accessories, though, was the Voyager Pro from Trail Tech. There’s little the Voyager Pro can’t do. From mapping new routes to uploading existing GPX trails and riding areas, you’re not getting lost and you’re not missing out on anything with the Voyager handy. The premium GPS even has a “Buddy Tracking” system that uses localized radio signals to see up to 20 riders in a single group at a time. See where your friends are riding, communicate via Bluetooth, or send an emergency beacon – all possible without even a hint of cell reception.

Trail Tech Voyager Pro

Finishing Touches

Fitted with just a few more accessories, the bike was ready to rip. An orange-accented Tusk Folding Shift Lever, Tusk Aluminum Brake Pedal, and Tusk Billet Bling Kit tied together the look of the bike, along with a fresh graphics kit from Attack Graphics. A lesser thought of accessory, the Tusk Grab Handle was also installed, adding a major convenience factor to the bike.

Tusk Folding Shift Lever

The Wrap-Up

We had a blast working with FMF and the other sponsors on this 2020 KTM 500 EXC-F. After they got the bike dialed-in and personalized, FMF came down to our neck of the woods, Southern Utah, to put the bike through some real off-roading.

Ripping the New Bike Over the Rocks

As you can see, it passed the test.

Check out the parts list below or visit the bike build sales page for even more suggestions for your 2020 KTM 500 EXC-F.


Tell Us What You Think

Be honest – how badly do you want a 500 EXC-F now? Did we leave any of your favorite parts off? Let us know in the comments below!

KTM OEM Parts Available at Rocky Mountain ATV/MC
Tusk D-Flex Pro Handguards Odi V2 Emig Pro MX Lock-On Grips Tusk Folding Shift Lever
Parts Available: Tusk D-Flex Pro Handguards Parts Available: Odi V2 Emig Pro MX Lock-On Grips Parts Available: Tusk Folding Shift Lever
Tusk Aluminum Brake Pedal Orange Tip Primary Drive Front Sprocket Primary Drive Rear Aluminum Sprocket
Parts Available: Tusk Aluminum Brake Pedal Orange Tip Parts Available: Primary Drive Front Sprocket Parts Available: Primary Drive Rear Aluminum Sprocket
Primary Drive 520 ORH Gold X-Ring Chain Tusk Racing Axle Block KTM Front Axle Puller
Parts Available: Primary Drive 520 ORH Gold X-Ring Chain Parts Available: Tusk Racing Axle Block Parts Available: KTM Front Axle Puller
Baja Designs XL80 LED Light Kit IMS Fuel Tank Rekluse RadiusCX Clutch
Parts Available: Baja Designs XL80 LED Light Kit Parts Available: IMS Fuel Tank Parts Available: Rekluse RadiusCX Clutch
Tusk Stainless Steel Typhoon Front Brake Rotor Tusk Stainless Steel Typhoon Rear Brake Rotor Tusk Brake Rotor Bolt Kit Front/Rear
Parts Available: Tusk Stainless Steel Typhoon Front Brake Rotor Parts Available: Tusk Stainless Steel Typhoon Rear Brake Rotor Parts Available: Tusk Brake Rotor Bolt Kit Front/Rear
Tusk Billet Bling Kit Tusk Grab Handle Trail Tech Voyager Pro GPS/Computer
Parts Available: Tusk Billet Bling Kit Parts Available: Tusk Grab Handle Parts Available: Trail Tech Voyager Pro GPS/Computer
Tusk Impact Complete Front and Rear Wheel Dunlop Geomax EN91 Enduro Tire
Parts Available: Tusk Impact Complete Front and Rear Wheel Parts Available: Dunlop Geomax EN91 Enduro Tire