How far can a KTM 500 really go?
KTM motorcycles seem to be a lightening rod for discussion and controversy in the dual sport adventure community. For example, critics often claim KTM bikes are noticeably less reliable than comparable Japanese bikes. Or that the maintenance requirements are excessive and time consuming. Fans counter with their own personal experiences, noting that their KTM bikes have not generally been less reliable than Japanese motorcycles. They also point out that the maintenance requirements printed in the owner’s manual are often based on using the bike in race conditions, not real world riding which typically is much less intensive and stressful on the motorcycle than racing.
Personally, I hesitated getting a KTM 500 EXC due to concerns about reliability, longevity, and maintenance intervals. My preferred riding consists of longer distance mixed surface riding – basically paved roads and dirt roads. I no longer do any racing, nor do I ride single track. Would the 500 be a good choice for the type of riding I do? Would the motor be up to relatively mild but long distance riding? Could it carry a week’s worth of gear without breaking the back of the bike? Or would I be asking the 500 to do something it just wasn’t meant or designed to do?
The persuading factor for me was my friend Tricepilot Bob. He bought a 500 a few years ago and has ridden it on lots of our trips, including our long distance Mexico rides (the longest of which was 1500 miles or so), without blowing up the motor, having to change the oil every day, or breaking the bike in half from carrying a week’s worth of gear. For me, the proof sure seemed to be in the pudding – the 500 appeared to be quite capable of handling the type of riding I envisioned for it.
So, I pulled the trigger and bought a lightly used 2105 model and so far it has exceeded my expectations.
But, still, how far can you ride a 500 before it needs motor work? The manual says to change the piston, valves, valve springs, valve spring seats, connecting rod, conrod bearing, and crank pin every 135 hours (70 if racing). For everyday riding, 135 hours equals about 4000 miles for me. Which brings up the question – what happens if I don’t do it every 135 hours? Is the motor going to throw the rod, seize the piston, or drop a valve seat at 136 hours?
I don’t know the answer yet since I don’t have that many hours on my motor. However, there is a guy named Aaron who has that and more and he has written a very interesting ride report on advrider.com that is well worth reading, especially if you are interested in how the 500 works for long distance, light weight adventure touring.
Aaron, on a 2015 KTM 500 EXC, stared out by riding the length of New Zealand. Once that was complete, he shipped his bike to the Santiago, Chile, South America and rode it from there all the way to Alaska. All in all he has covered more than 37,000 kilometers and has more than 510 hours on his motor. Other than changing the oil regularly and keeping the air filter clean he has done no motor work. He did have the valves checked when he made it to San Diego, CA and they were in spec. He says the motor is running good and not using oil.
Pretty impressive, I’d say.
While I freely admit that his is an experiment of one – it’s possible that his 500 is exceptional and far outside the norm – it is also possible that his 500 is representative of the species. In other words, the motor in the 500 could be quite robust and not likely to need an overhaul every 135 hours.
After reading Aaron’s story, I am less concerned about the need for motor work every 4000 miles. I think I will just change the oil on mine regularly, keep the air filter clean, and see how things go.
I purchased a 2014 exc 500 in summer of 2016 with 50 miles on it. I put a acerbis 5.3 gallon tank on it, and routinely do 200 mile day rides. Longest day ride of 350 miles. Think biggest weekend was 750 miles. All on gravel or single and two track. I did 1500 to 2000 mile oil changes. At end of 2017, I have 7800 miles and 262 hours. Getting oil consumption and currently in process of rebuilding motor. Prior to this bike I had a 450xcw that I did 1000 mile oil changes and did not have oil consumption at 8500 miles when I traded it off. I know people with over 10k on their machine, running fine. Given what I know now, I will return to 1000 mile oil changes.
Thank you for sharing your experience with the 500. It sounds like you and I ride our bikes similarly (with the exception of single track). A 200 mile day is pretty typical for me, consisting of both paved and off-pavement riding. I have around 6500 miles on my bike so far and have been doing oil changes every 1000 miles. No oil burning yet.
Cheers,
Rich
I have a 2013 500exc, which unfortunately has seen less riding than expected and 2 years sitting idle (back on it again now). Still, I have over 500 hours and 20k miles on it without ever looking at the valves. Isn’t starting as easy these days, but planning on a valve check and expecting that to remedy it. Oil changes at 2,000 +/-. Always wanted to send oil in for analysis, but never have.
Any update how is the bike running this days? I’m in the same process adventuricing my 2016 KTM EXC-F 500
I still have the bike – which is near miraculous since I tend to only keep bikes about 2 years before moving on to something else. At just over 10,000 miles on the odometer the bike started to smoke a little bit so I had my local KTM dealer do a top end job (piston and rings) on it last month. Aside from that I have not had any issues with the bike.
Have bought Husky fe501s 2.5 months ago. Riding daily around 50km in Bali (temp ~ 30C), changing an oil every 15 hours (2 weeks/700km). Already 3.3k km. So good so far.
I have a 2015 EXC 500 with 10,00 miles 525 hours I change my oil every 3-400 miles all off road miles. I’ve checked the valve clearance 3 times every time still on the money Just recently I have noticed some oil burning smell out the exhaust but with no noticable consumption between oil changes I am considering a new piston and rings this year
I have a 2020 exc-f 500 at 220 hours
Over 12000 km never had to adjust the valves
Oil change done a little less than
1800 km no problem
Drives like new Perfect bike
I have a 520 2000, I purchased it third hand not sure how many kms on it. I have put about 4000 on it. I change the oil and filters regularly. It runs sweet uses no oil and no smoke at all. It is a great bike. I would rebuild it if there were any signs but it simple runs like new. So unless it starts to loss power, smoke or i find bits in the filter i am just going to enjoy it.
I have a ktm 500 exc 2020 with on hundred billion miles on it, and I change oil every five minutes
I have a 2015 500 with a bit over 22k km and ~450 hours. Previous owner had changed piston and rings while changing countershaft bearings (nothing else) at ~250 hours.
Last Winter I decided to check the top and bottom ends preventatively. Change the main bearings, a few other case bearings (preventative), intake valves (worn), 4 valve springs (1 out of spec), both oil pumps (preventative), all tranny gears bearings/clips/shim washers (preventative), cam rockers/pins (preventative recommended by mechanic) and piston rings (always a good practice when opening top end). No piston and no crank. 40+ years KTM experience mechanic looked it over and said all looks like new in there (excpt 2 chipped tranny gears 😐 ). I did all work myself, except case split and tranny, and it cost me ~$3k in parts (I’m sure I changed things that I could not have bothered to, but, since it’s all apart, it’s cheap insurance).
Bike never burned oil, and valves did need shims changed 3 times since I’ve had it (~175 hours, once after rebuild likely due to seating).
Oil changes done every 15-25 hours depending on riding conditions, and air filter changed accordingly too (1-2 rides). I ride mostly 1 & 2 track with some dirt roads, very little asphalte.
Hope my experience help you out 🙂
P.S. I like the 500 so much that I also bought a 2017 😉 I ping pong between both.