The Ultimate 17-19 KTM 500 / Husky 501 Bike Build

 
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A very common question we get from riders who are planning to buy a new bike is this:

“Which is better? The new 2017-19’s, or the older 2013-16’s?”

The answer is, they both can be made spectacular. It costs a bit more to get the power levels of the newer bikes up to the levels of the older ones, but… if money isn't your biggest concern, then we’d suggest getting the newer 2017-19 bikes (or the new 2020’s if you can).

The main reason is because after riding both in enough back to back situations, there’s a noticeable feeling of confidence you get from the newer bike’s frame and suspension.

In our opinion, that extra feeling of being in control is worth paying the extra money for.

If you don’t have the opportunity to experience the 2017-19 KTM / Husky bikes for yourself, watch the videos on this site, or on our YouTube Channel because they are amazing!

With that said, if you are planning to, or already own a 2017-19 bike… let’s dive into the Ultimate 17-19 KTM 500 / Husky 501 Bike Build.

Why We Created These Products

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 like to flame out and stall.

If this sounds about right, then it’s not just your imagination.

And if you just keep riding your bike hard with all the stock parts… you may cause yourself some expensive problems like:

  • Damaging expensive or hard to replace parts.

  • Injuring yourself because your motorcycle stalls at the worst times, or just isn’t as responsive as it needs to be in certain situations.

  • Overheating, breaking parts, and getting stranded in the middle of nowhere.

So the whole existence of this site… is to help you fix all the annoying problems you just inherited, at the most cost effective prices possible so you can be in love with your new bike (instead of frustrated or disappointed).

These products are all designed by real riders, for real riders. All we do day in and day out, is address these issues by creating the most innovative products, that you won’t find anywhere else on the market.

Not to mention, everything we do is tested and verified on the dyno, which is the only way to really know how well a product performs.

So now let’s take a look at how plugged up the new 2017 - 2019 KTM/Husky's really are, compared to the horsepower gains you’ll get when compared to the bikes with our kits installed.

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

The blue line above shows the power and torque numbers from a 2017 500 EXC at wide open throttle in 4th gear. It’s making about 48.6 horsepower stock.

The orange line is how much power you can get out of the bike with our kits. Which is about 59.3 horsepower!

That’s a HUGE 10-hp gain considering the size and weight of these newer bikes. Just looking at these power curves above should get your blood pumping, when you imagine how strong and healthy your motor is going to pull.

So now that you can see what the dyno chart confirms, let’s cover a question that many riders ask when buying products from this site.

How To Approach Your Ultimate Bike Build

There are two ways to go about things when you build your dream bike, and we suggest option one below. Because why toe dip, if you can afford to dive right in and get everything your bike needs.

Here’s your options:

1) Buy the most “Premium” bundle kits you can afford. You’ll save lots of money and get the most bang for your buck performance-wise, for a completely transformed bike - all in one shot!

Or…

2) Buy the individual components. This method let’s you save up while you build your bike a few parts at a time, and learn about all the performance improving mods you can add to your bike over time.

Just keep in mind, when you start modifying things, you may need other components for them to work optimally. So if you plan to RIDE your bike right away, rather than just add parts in the garage as a fun project… then we highly suggest the bundle kits.

So the next few kits below are our most premium bundle kits we recommend because they’re what we use on our own bikes. They contain every single component we make for the Ultimate Bike Build, and they complement each other perfectly.

*We understand some people only want to add small things like fuel filters, especially if you live in certain parts of the world where fuel quality is an issue. We made those smaller options available by themselves, and you can find those further down the page.

OK, let’s get started!


Power Bundle + Fuel Programmer Kit

If you’re ready to invest a little more in your bike, so you can get it to perform the way you expected it to when you bought it, this Power bundle + fuel programmer kit will get you there the fastest!

Installing this kit will absolutely transform your bike, and leave you wondering how you ever rode your bike without it. Here’s a quick peek at what’s in the kit, but the rest of the page will go in more detail on each individual component.

 
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The “Power Bundle + Fuel Programmer" Kit Includes:

  • Fuel-Ratio Programmer

  • Power Intake Tube

  • Grunt Exhaust Manifold

  • Exhaust End Cap (Silver or Black)

  • 90-Degree Fuel Tank Fitting

  • High Capacity Fuel Filter

  • High-Flow Fuel Rail

  • Closed Course Emissions Delete Kit (*By buying and installing this component, you assume full responsibility for abiding by all motor vehicle laws in your area)

Every component in this bundle kit is designed to work perfectly together. At a minimum, we suggest starting with this kit because it will make all the other additions a breeze to add on without affecting anything.

Each of the parts is explained in more detail further down the page, but if you trust us that this really is the most performance improving kit you can buy to start your Ultimate Bike Build on the right foot, you can just buy it now - then learn about everything while your parts are in the mail!

If you want to get everything you see in this Power Bundle + Fuel Programmer kit now, as well as detailed installation instructions, you can buy it below now for only $699.95.

If you already have an aftermarket exhaust, and you want to save a few bucks, you can pick up the Power Bundle with No End Cap Below. And in case you’re wondering, the programmer works great with any aftermarket exhaust just as well as it does with our End Cap.

 
 

Alright, now the next few kits are what we would still consider part of our premium bundle kits for the Ultimate Bike Build because they go perfectly with the first kit above. Read on below to see if you want to add them to your cart before checking out.


Clutch Cover and Clutch Weight Bundle

Large capacity clutch covers and clutch weights are gaining popularity because they keep your clutch components protected and healthy for longer, and they keep your motor running better by preventing your bike from stalling or flaming out.

So let’s take a look at them one at a time, and we’ll cover how they work together perfectly.

The Clutch Covers

Our Big Oily Clutch Cover is made from billet aluminum and offers superior protection against impact damage. It also allows you to add up to 9 more ounces of clutch oil!

The main benefit of having more clutch oil is having more space for metal fragments to move away from moving parts, reducing long-term wear and tear.

Most importantly, it gives you enough space to fit our large 15.8 Ounce Clutch Weights! (more on those in a moment)…

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If you look at the pictures above, you’ll see they are designed for ultimate durability to protect your bike.

You’ll notice we also dded an additional reservoir at the bottom, to trap any loose metal shaving debris floating around in the clutch oil.

This will increase the life of your clutches moving parts. You can get the Big Oily Clutch Cover by itself elsewhere on our site for only $149.95… but for our suggested Ultimate Bike Build we highly recommend getting the bundle pack with the clutch weights below.

The Clutch Weights

Clutch Weights have become a favorite for riders because they add significant rotational mass to your engine, which makes for less flame outs and better bottom end traction.

The image on the left is the clutch in stock form. And on the right is one of our cutch weights bolted on the outside of the stock clutch assembly.

 
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If you’re mechanically inclined enough to remove a clutch cover, tighten a few bolts, and replace the oil… this product is a must-have.

We offer two different sizes:

  • 15.8 oz. Clutch Weight (only fits in our Big Oily Clutch Cover mentioned above).

  • 11.2 oz. Clutch Weight (this is our most popular clutch weight size for a 500 cc bike, as it’s designed to be most effective in tighter single track situations - and it works with your stock clutch cover).

At this point, all you really need to know is which size is best for your bike.

The larger 15.8 clutch weight size helps with throttle control, traction, and the herky-jerkyness these 500 cc bikes seem to have, and significantly reduces flame outs and stalling.

But it’s really just a matter of preference, and most people buy the 11.2 oz. clutch weight because they want a safe “middle of the road” option, that works best for most situations (especially tight single track).

You can get the Big Oily Clutch Cover and Clutch Weights bundle pack (in the 15.8 or 11.2 ounce option) below for only $174.95:

 
 

The “In-Tank Fuel Filter / Fuel Pump” Bundle

Part 1) The In-Tank Fuel Filter

One of the biggest frustrations we hear from riders and professional race teams is the inadequacy of “stock” in-tank fuel filters.

In case you don’t know what they are, they are like the first line of defense for the fuel entering your bike.

Not only are the stock in-tank fuel filters the wrong size and filtration level for these bikes, if they break inside your tank from riding aggressively, you’re going bike is going to be running poorly or not at all!

And it’s almost impossible to find a better solution anywhere, so we sourced our In-Tank Fuel Filters from Taiwan, because the ones from China are no good.

Take a look at how our yellow filter looks, compared to the stock brown one in the image below.

 
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You’ll notice ours has twice the surface area. It’s also a much more appropriate 10 micron filter. Cars use 5 micron filters, and the stock ones in your bike use 40 micron. So obviously that’s letting way too large of particles through.

There’s a few other filters on the market that may seem like they would work, but be careful because they most likely can’t handle the 50 psi pressure the fuel injection system uses.

Also - we test each in-tank fuel filter before shipping it out to you, just for quality assurance.

So unless you want to deal with having to rebuild your filter because the filter elements get blown out, which does happen to high performance bikes… then we suggest just getting our tried-and-true filter replacement.

Next let’s talk about the fuel pump that’s also included in this bundle.

Part 2) The Fuel Pump

The stock fuel pumps that come on the new bikes are made in China and don’t work very well. Our fuel pumps are much better in quality, performance, and reliability.

Also - we test each fuel pump before shipping it out to you, just for quality assurance.

You can get the In-Tank Fuel Filter and the the Fuel Pump bundle below for only $174.95

 
 

Anti-Vibration Wheel Balancing Weights

 
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If you’re making your bike faster... you're definitely going to want to add our stainless steel WHEEL BALANCING WEIGHTS, to eliminate speed wobbles!

Just like with the 2012 - 2016 bikes, KTM and Husky still insist on putting the rim lock and valve stem close together. This makes the wheels unbalanced causing them to shake your bike around at speeds over 50 mph (which is obviously unsafe).

Our wheel weights bolt right onto the spokes, directly across from the rim lock and valve stem to balance the front and rear wheels enough to smooth out your ride up to 100 mph.

And they're designed to stay in place even in extreme off-road conditions!

I suggest grabbing a set of our WHEEL BALANCING WEIGHTS if you plan to ride on the street over 50 mph. You can buy them below for only: $14.95 each

 
 

Handguard Strong Bar Ends

The smartest idea in wrap-around hand guard technology, since the idea of the wrap around itself, is our new Strong Bar Ends that fit all KTM and HUSKY stock handlebars.

They fit inside of your handlebars much tighter than others you might find.If you’ve ever crashed and had your bar ends spin around inside the handlebars as you try to tighten them, then you’ll appreciate how this design doesn’t allow the part inside the handlebar to spin.

For the price, it’s a no brainer to pick these up. The outer diameter is .550" or 13.8 mm. It fits all handguards from Cycra, Barkbusters, Acerbis, Enduro Engineering, and Zeta (as well as several others).

You can get them below for only $29.95.

 
Handguard Strong Bar Ends
29.95
Quantity:
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The Best Radiator Guards and Braces

Now for the final piece to protect your Ultimate Bike Build… our Radiator Guards and Radiator Guard Braces are better than ANYTHING you’ll find on the market.

Not only are these radiator guards extremely durable, but the braces that hold them on, are designed to NOT rip off your radiator guards even in the roughest situations and crashes.

You can buy this practically indestructible pair below for only $184.95 and $59.95.

 
Radiator Guard Crossbar in Black
59.95
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This Concludes OUR Ultimate KTM / Husky 500-cc Bike Build!

If you were to install every bundle we covered above, you’d be riding OUR own Ultimate Bike Build setup. We hope you’re as happy with all of these parts installed on your bike as we are!

Now, if you’re looking for a little more info on the individual components… and also a more affordable way to build your bike a few parts at a time, you can see our Individual Components and smaller Bundle Packages below.


Individual Components / Small Bundle Kits


Here’s the BIGGEST question many new customer’s ask us…

"What is the first thing I should do to my bike? I just bought it, it's stock, and I don't really want to void the warranty."

Well, that's a good and intelligent question. The answer is, more than anything, the bike needs more fuel to it. In the stock condition, it runs way too lean at all throttle openings, and even at idle.

You’ll have a few options below at different price points. Some will affect your warranty, and others will not.


The “Fuel-Ratio Programmer”

The Most Cost-Effective Way To Get Optimum Fueling is by using our Fuel Ratio Programmer. (This part is included in the Power Bundle + Programmer kit above)

This is our version of a piggyback programmer for the 2017-19 500/501. These are made by a company that makes them for many people, so the design may look similar to others.

BUT - that's where the similarities stop.

All of the programmers have 6 zones you can play with as the end user, but that just gives you an ability to only slightly fine tune things.

What separates our fuel programmer from the others is all the hard work and time that it takes to get the baseline numbers in place.

We spent a lot of time on the dyno and in real-world riding situations, to come up with great baseline numbers for various situations and bike modifications.

And we're the only ones who have the power and fuel numbers to back up our claims of being the best with these programmers. So they will work for any stage you’re at with your bike build.

Pick one up below, with full detailed instructions for only $219.95

 
 

The “Power End Cap”

Now that we have the right fuel going to the bike… let’s talk about opening up your exhaust using our Power End Caps. (This part is included in the Power Bundle + Programmer kit above)

Everyone thinks they need to spend $400+ on a brand new aftermarket exhaust pipe, but the truth is your money is better spent elsewhere.

By using our Power End Cap you can start getting additional power out of the bike, and at the same time, you can protect the engine from overheating - at less than half the price of an aftermarket pipe.

What Stock Exhaust Pipes Look Like Inside…

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This is a stock end cap. The muffler is new for 2017-19, and even more restricted than the 12-16 mufflers.

These stock pipes are plugged up at the intake and exit side of the outlet tube. This results in a huge loss of power, and causes significant pressure and heat build up in the engine.

Restricting the exhaust on 500's this much is actually dangerous so you're definitely going to want to install our Power End Cap to alleviate this issue.

What Our “Power End Caps” Look Like Inside…

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Our Power End Cap is highly free flowing compared to the stock end cap, and makes the stock muffler work great - while still being nice and quiet.

The other great thing is your exhaust will no longer burn your stock turn signals as there's less heat build up.

It comes with a spark arrestor built in, and an optional quiet insert (included).  And even with the quiet insert installed, you'll still be making the same power as an aftermarket slip on exhaust.

If you want to get one by itself, they're available in silver and black below for only $189.95.

 
Power End Cap for 2017-19 FE in Silver
149.95 179.95
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Power End Cap for 2017-19 FE in Black
149.95 179.95
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     The “Power Intake Tube”

These newer bikes actually have the reed cage, and reeds from the 2 strokes installed in the intake tract when you get it from the factory. Yes, you heard that right.

In an effort to quiet the bike down from intake noise, they put reeds between the air filter and throttle body.

The Stock Intake

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Not only are these a huge restriction in air flow, and a significant power reducer… but they are also a danger if they break.

It's in your best interest to remove the reeds, and replace it with our Power Intake Tube which is a very easy install. (This part is included in the Power Bundle + Programmer kit above)

Our Power Intake Tube

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Lots of testing went into the precise length, shape, and diameter of our custom intake tubes, resulting in the ultimate throttle response, and mid-range to top-end power.

Installing our tube is an instant 4 horsepower gain from 6,000 rpm to 10,000 rpm's, and also provides stronger and snappier acceleration.

It's really a no brainer when it comes to uncorking the first part of your bike’s breathing system. To pick on up by itself, you can get it below for only $69.95

 
 

The “Grunt Exhaust Manifold”

For solid gains in throttle response and pulling power from right off of idle, and through the mid range, you're going to want to add our world-renowned GRUNT EXHAUST MANIFOLD. (This part is included in the Power Bundle + Programmer kit above)

 
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Our Grunt is the manifold on the left, stock is on the right.

The smaller and better shaped inner diameter is what gives the bike the increased response and pulling power. And the O-Rings on the outside create a tight seal between the head pipe and manifold, to avoid sucking air at the head pipe joint.

You can buy the Grunt Exhaust Manifold below for only $99.95.

 
 

The "Big Bottom" Kit

Most people just opt to get the Big Bottom Kit pictured below.  It's the bundle pack of the Power Intake Tube and the Grunt Exhaust Manifold. (This part is included in the Power Bundle + Programmer kit above)

You save money when you buy them together, and it’s a good option when you're on a budget.

You can get the Big Bottom Kit below for only: $149.95

 
 

Now we'll go over some really trick mods you can think about adding, for that extra bit of performance and functionality your high performance bike deserves. Read on below...


Fixing the Fuel Delivery System

Our High-Flow Fuel Rail is probably our #1 seller overall because it's so affordable, and quickly changes the way your bike moves fuel from the tank to the fuel injector. (This part is included in the Power Bundle + Programmer kit above)

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The picture on the left, shows my fingers on the stock fuel rail.  The fuel comes into the injector at more than a 90 degree angle, has to turn and go from a large chamber into the small hole of the injector. This doesn't work too well for strong fuel flow.

Problems that result from this set up are decreased instant acceleration, flameouts, stalling and hard starting.

Our fuel rail, which you see in the picture on the right, gives as straight of a fuel pathway as possible. This is a small part, with big benefits.

You can get the High-Flow Fuel Rail below for only: $74.95

 
Fuel Rail for all 2017-20 KTM and Husky
49.95 74.95
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90-Degree Tank Fittings

The next piece you'll need to improve your fuel system's flow, is replacing the stock 90-degree fuel fitting under the gas tank with our better flowing 90-Degree High Flow Fuel Tank Fitting. (This part is included in the Power Bundle + Programmer kit above)

It may seem like just another small part, but the stock one just doesn't flow enough for high speed running and the bike's fuel ratio still leans out at this crucial intersection.

It’s also worth mentioning that this part will still fit your oversize tank if you decide to install one later. You can get the 90-Degree High Flow Fuel Tank Fitting below for only: $64.95

 
 

Large Area Fuel Filter

Next up is our Large Area Fuel Filter. (This part is included in the Power Bundle + Programmer kit above)

Not only does it replace one side of your quick disconnect, to save room, but it also has a filter capacity of 6 times larger than the stock filter.

 
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Add the LARGE AREA FUEL FILTER to your fuel rail, and 90 degree fitting purchase for the ultimate fuel delivery system possible for only: $59.95

 
Quick Disconnect / Large Area Fuel Filter
44.95 59.95
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Closed Course Racing Emissions Delete Kit

(FOR CLOSED COURSE COMPETITION USE ONLY)

This kit fits 17-19 FE-S and EXC-F models that came with emissions devices on them. It contains all you need to remove the air injection valve and all hoses. (This part is included in the Power Bundle + Programmer kit above)

The solenoid valve on top of the crankcase must remain plugged in if using the stock ecu, but you can zip tye it up in the air box, so it's out of visual way.

 
 

Fuel Filter and Fuel Pump (Individual Components)

These are the same fuel filter and pump parts mentioned in the bundle kits above, as well as the replacement parts to rebuild them if ever needed.

 
KTM / Husky Fuel Pump Line
12.99
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In-Tank Billet Fuel Filter Rebuild Kit
24.95
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This Concludes Our Bike Build Page

Thanks for checking out our bike build, and learning about all the different ways you can improve your bike’s performance!

Again, if you have any questions at all, please feel free to email us at: sales@bestdualsportbikes.com

We hope you enjoy these products as much as we do, so you can “Smile bigger after every ride!” :)