NOTE - THIS IS AN EARLY 2025 DRAFT DOCUMENT AND SOME NUMBERS AND DATA ARE SUBJECT TO

CHANGE

Performance and Drivablity Enhancements for

the KTM, Husqvarna, GASGAS Enduro Bikes
Models Covered In This Article
2020+
KTM 350, 500
EXC-F, XCF-W, XW-F

2020+
Husqvarna 350, 501
FEs, FE

2024+
GASGAS 350, 500
ES, EW

In North America these bikes are classified as emissions controlled street legal
(50-states) motorcycles (EXC-F, FEs, ES) or Green Sticker public lands compliant
sound and emissions controlled off-road bikes (XW-F, FE, EW)

To meet federal requirements these machines have the following sound and control
systems:
●​ 80% air-obstructed muffler end cap
●​ Two-stroke intake reeds in the air intake boot
●​ Fuel tank vapor recovery and recycle system
●​ Narrow band 12mm lambda (o2) sensor
●​ ECU mapping to match restricted airflow volumes

Some riders will seek to convert their machine from road and trail legal to a closed
course competition use only bike with the following goals:
●​ Increase engine sound
 ●​ Improve throttle response and power
●​ Reduce engine heat
●​ Weight reduction
●​ Reduction of failure points

When converting one of these machines to a closed course competition use only
motorcycle the following options could be considered:

INTAKE SYSTEM
INTAKE REEDS $0
Advantages of Removal
●​ Increased airflow for more power through the rev range, particularly in the
mid-range and top-end
●​ Reduces potential failure points as the carbon fiber reed petals have been
documented to break off and be sucked into engines damaging intake or
exhaust valves
●​ Eliminates the possibility of them popping out and being sucked in backwards
cutting off airflow to the engine
●​ No cost mod

Disadvantages of removal
●​ Reduces some low-end torque and smoothness
●​ Increases intake sound
●​ Will lean out the Air Fuel Ratio (AFR) if fuel corrections are not made

VAPOR RECOVERY SYSTEM DELETE $0-$99

The hoses and control solenoid have no effect on the power of the engine
Advantages of removal
●​ Removes failure and maintenance points
●​ Saves a very slight amount of weight
●​ Low to no cost mod

Disadvantages of removal
●​ Increased fuel vapor smell which will be very noticeable in closed garages,
vans and trailers

INTAKE VELOCITY STACK TUBE $70

Contrary to popular myth, removal of the intake reeds will not cause the intake air
boot to collapse on itself. Additionally exaggerated claims of power gains have not
been proven out by us in dyno and ride testing. In fact the opposite has been shown
to be the case with a power loss on some bikes at certain RPM’s.
These tubes are sold on the internet and marketed on youtube, Taco Moto does not
and will not make these and we maintain a strong recommendation of do not buy on
these products.
Advantages of installation
●​ None that can be measured or documented

Disadvantages of installation
●​ Unnecessary cost
●​ Our testing showed a 2-8hp power loss across the powerband depending on
the bike and the tune.
​
REMOVAL OF AIR FILTER BACKFIRE SCREEN $0-$18
Contrary to popular myth there is no performance advantage besides placebo power
to be gained by removing the stainless steel mesh backfire screen on the air filter
cage. Additionally the need for a backfire screen on a fuel injected bike is no longer
a practical concern
Advantages of removal
●​ None

Disadvantages of removal
●​ None

EXHAUST SYSTEM
STOCK MUFFLER END CAP MODIFICATION $0
The stainless steel end cap on the stock muffler has an air obstruction bung that
restricts airflow by 80% and has an outlet final diameter of 26mm. Multiple options
exist for increasing stock muffler air flow. Some riders will cut out the restriction and
knock out the ‘cheese greater’ plug at the end.
Advantages of removal
●​ Increased airflow for more power through the full power band
●​ Increased sound output
●​ Increased airflow allows the engine to run more efficiently and cooler
●​ Retains the stock look of the exhaust system
●​ No cost mod

Disadvantages of removal
●​ Increased sound output
●​ If not done correctly, this mod will void spark arrestor compliance
●​ 26mm outlet will limit full possible power potential
●​ Will lean out the Air Fuel Ratio (AFR) if fuel corrections are not made

STOCK MUFFLER CONE RESONATOR $0

Inside the OEM muffler is a perforated cone-shaped screen called a resonator. This
device is designed to dampen specific drone frequencies in the exhaust sound
profile.
Advantages of removal
●​ Increased airflow for more power in the mid range to top end
●​ Increased sound output
●​ No cost mod

Disadvantages of removal
●​ Increased sound output
●​ Increased annoying engine drone sound
●​ Time consuming and difficult to remove
●​ Loses noticeable power, smoothness and torque in the bottom end and
mid-range

Who benefits the most from removal

●​ Fast, wide open riders
●​ Snow bikes, MX bikes, super moto, wide open desert racers

PRO MOTO BILLET END CAP $159

This is a full replacement end cap with an optional and very effective ultra silent
insert $57
Advantages
●​ Increased airflow for more power through the full power band
●​ Increased sound output
●​ Increased airflow allows the engine to run more efficiently and cooler
●​ 42mm outlet diameter extracts the full power potential from the exhaust
system

Disadvantages
●​ Increased sound output
●​ Will lean out the Air Fuel Ratio (AFR) if fuel corrections are not made

FMF 4.1 MUFFLER $549 - $749

This is an aftermarket slip-on muffler available in an aluminum and titanium version,
and is known for very loud sound and very punchy, hard hitting power. Sound can
be slightly reduced with the installation of a spark arrestor sound baffle.
Advantages
●​ Increased airflow for more power through the full power band
●​ Increased sound output, this system is quite loud
●​ Increased airflow allows the engine to run more efficiently and cooler
●​ Ideal for high speed wide open riding like super moto, snow bike, desert
racing, etc.
 ●​ Weight savings of up to 1.1lbs over stock

Disadvantages
●​ Increased sound output
●​ Snappy and harsh low end power in trailing throttle conditions
●​ Not ideal for technical hard enduro riding conditions, technical off road terrain
●​ Cost
●​ May melt turn signal
●​ Fragile carbon fiber end cap
●​ Will lean out the Air Fuel Ratio (AFR) if fuel corrections are not made

GRAVES MUFFLER $725

This is an aftermarket slip-on muffler available in titanium and is known for very
strong and smooth power throughout the rev range. Includes a removable DB killer
/ spark arrestor.
Advantages
●​ Increased airflow for more power through the full power band
●​ Increased sound output
●​ Increased airflow allows the engine to run more efficiently and cooler
●​ Ideal for all levels of riding and is one of the best ‘all around’ muffler choices
●​ Weight savings of up to 1.3lbs over stock

Disadvantages
●​ Increased sound output
●​ Cost
●​ Fragile carbon fiber end cap
●​ Will lean out the Air Fuel Ratio (AFR) if fuel corrections are not made

YOSHIMURA 2024-2025 MUFFLER ONLY $699

YOSHIMURA 2020-203 FULL SYSTEM $1,069
This is an aftermarket slip-on muffler (24-25) and full system (20-23) is available in
stainless and is known for very strong and smooth power throughout the rev range.
Includes a removable DB killer / spark arrestor.
Advantages
●​ Increased airflow for more power through the full power band
●​ Increased sound output
●​ Increased airflow allows the engine to run more efficiently and cooler
●​ Suitable for all levels of riders
●​ Weight savings of up to .3lbs over stock

Disadvantages
●​ Increased sound output, this system is quite loud
●​ Weight, nearly as heavy as the stock system
●​ Cost
 ●​ May melt turn signal
●​ Fragile carbon fiber end cap
●​ Will lean out the Air Fuel Ratio (AFR) if fuel corrections are not made

ECU’s, TUNERS, MAPPING

The stock ecu map / o2 sensor is calibrated to the limited air flow of the stock intake
and exhaust systems already discussed.

The narrow band o2 sensor works to trim the AFR during the cruise zone to 14.5 -
16.5 range.

Contrary to popular myth these bikes are not an unlimited ‘auto tune’, as the
automatic trim adjustments are not permitted to bring the AFR down into the 13-14
range for the best and safest power.

Nor is the narrow band o2 fast enough to respond quickly enough to trim the fuel
across all rpm’s, hence the ecu going into closed loop only in the cruise zone.

It should be noted that we’ve logged AFR’s in the upper 17’s on the stock ECU with
an open exhaust and the reeds removed. This is much to lean for safe engine
operation and power will be weak and erratic with hard starting, stalling and
backfiring being the typical results.

Bellow are the most popular and trusted methods for fuel correction:

DOBECK EJK PIGGY BACK TUNER $249

A ‘piggyback tuner’ is an electronic device that plugs in series between the bike and
the fuel injector and depending on the programming increases or decreases the
injector on time (duty cycle) to reach a target AFR at a given rpm
Advantages
●​ Low cost
●​ Easy installation
●​ Fuel trims can be user modified with on board mode buttons
●​ Smooth running ‘warm’ linear power
●​ If the unit fails it can be bypassed

Disadvantages
●​ Adds complexity and hardware to the bike
●​ No ignition timing adjustment
●​ Not able to provide single track map
●​ Modest performance gains which can be bested by other more costly options

TACO MOTO STOCK ECU REFLASH $349

Launching in March of 2025 this service will allow a rider to ship in a stock ecu to be
reflashed with a tune profile specifically configured for an open exhaust, reeds out
set up. Will be a available for the 17+ Austrian four stroke enduro bikes
Advantages
●​ Low cost
●​ Easy installation
●​ Adjusts fuel and ignition
●​ OBD2 enabled
●​ No additional installed hardware
●​ Allows for installation of optional map switch on 24+ bikes that add dual
maps, quick shift, and traction control $169
●​ Retains the stock Kehein ecu
●​ Lifetime Taco Moto map support

Disadvantages
●​ No user adjustable fuel or ignition trim capabilities
●​ Must be sent back to Taco Moto for map mods if needed

DYNOJET POWER COMMANDER $434

A ‘piggyback tuner’ is an electronic device that plugs in series between the bike and
the fuel injector and depending on the programming increases or decreases the
injector on time (duty cycle) to reach a target AFR at a given rpm. The PC system
allows for better fuel tuning and control than other piggyback tuners and offers best
in class features and capabilities.
Advantages
●​ Low to moderate cost
●​ Easy installation
●​ Fuel trims can be user modified with free Dynojet tuning software
●​ A bike can be custom fine-tuned at any of the hundreds of motorcycle shops
across the country equipped with Dynojet dynos.
●​ Available map switch witch allows salvation of an economy map
●​ Available quick shift feature with optional shift sensor $149
●​ Available autotune capability with 18mm wide band o2 sensor $367
●​ Very clean and accurate fueling
●​ Very little power loss compared to a full race ecu
●​ If the unit fails it can be bypassed to complete the ride

Disadvantages
●​ Adds complexity and hardware to the bike
●​ No ignition timing adjustment
●​ Not able to provide single track map

TACO MOTO FLASH AT HOME STOCK ECU REFLASH WITH THE

DYNOJET POWER VISION DEVICE $699
Launching in March of 2025 this service will allow a rider to reflash an ecu at home
with the Power Vision device. Will be a available for the 17+ Austrian four stroke
enduro bikes
Advantages
●​ Easy to use
●​ Adjusts fuel and ignition
●​ OBD2 enabled
●​ The Power Vision device can be used to flash additional maps to this or any
other supported dirt bike, street bike, UTV and more
●​ The PV device is a powerful scan / diagnostic tool
●​ Allows for installation of optional map switch on 24+ bikes that add dual
maps, quick shift, and traction control $169
●​ Retains the stock Kehein ecu
●​ Lifetime Taco Moto map support

Disadvantages
●​ None

AIM RACE ECU $699

The lest known of all the aftermarket ecu’s but a good value and equipped with
some class leading features and capabilities
Advantages
●​ Easy installation
●​ Adjusts fuel and ignition mapping for the most power possible
●​ Multiple maps from race to single track
●​ Fuel trims and five mode traction control can be user modified with optional
LED map switch $189
●​ Fuel, ignition and other ecu functions can be modified in the free AIM user
software and uploaded to the bike with a low cost programming cable $120
●​ Optional SOLO 2 system allows for data collection and live AFR monitoring
and modifications $649
●​ Available low cost toggle map switch $69
●​ Available quick shift feature

Disadvantages
●​ Early units had reliability issues

VORTEX RACE ECU $799

The best know of all the aftermarket ecu’s
Advantages
●​ Easy installation
●​ Adjusts fuel and ignition mapping for the most power possible
●​ Multiple maps from race to single track
●​ Single mode traction control on some models
●​ Fuel trims adjustable by on board rotary dials
 ●​ Fuel, ignition and other ecu functions can be modified in the programming
software and cable $1,009
●​ Launch control button $105
●​ Available toggle map switch $69
●​ Available quick shift feature

Disadvantages
●​ Cost

GET SX1 RACE ECU $825 - $1,038

The best performing and best equipped ecu system available today with features
and capabilities no other system can offer.
Advantages
●​ Easy installation
●​ Adjusts fuel and ignition mapping for the most power possible
●​ Multiple maps from race to single track
●​ LED map switch allows for management of two maps, ten modes of traction
control, overheat warning and launch control
●​ Fuel, ignition and other ecu functions can be modified in the wifi enabled
smartphone app
●​ OBD2 enabled
●​ Available toggle map switch
●​ Built in on board barometric pressure sensor
●​ If purchased from Taco Moto includes lifetime map and ecu hardware
warranty

Disadvantages
●​ Cost

Free things to do to decrease stalling:

●​ Run the idle speed +200 rpm over spec
●​ Run in a lower gear
●​ Run a lower gear ratio
●​ Practice improved clutch management skills

REAL POWER TESTING NUMBERS FUEL MAPPING

CORRECTION
In stock form, the following bikes make the following power:

2025 KTM 350 EXC-F

Taco Moto Dynojet 168 series dyno
2300 feet elevation
74 deg F
Slick rear tire, 30 psi

Stock configuration
36hp at the wheel

Modified configuration
47hp at the wheel

2024 KTM 500 EXC-F

Taco Moto Dynojet 168 series dyno
2300 feet elevation
77 deg F
Slick rear tire, 30 psi

Stock configuration
38hp at the wheel

Modified configuration
57hp at the wheel

QUESTION / ANSWERS
DISCLAIMER - Removing or modifying any sound or emissions control system or device will
make a vehicle illegal to drive on public roadways. Any parts, systems, modifications or similar
described in this article are strictly for converting a motorcycle into a Closed Course
Competition Use Only Machine. These modifications are not Intended for street use and do not
conform to CARB / EPA laws and regulations and are not legal for use upon a highway. These
modifications are NOT California ON-ROAD approved for CARB E.O. D-654 requirements.

Taco Moto makes no claim of fitness or serviceability of any of these modifications or

adjustments and each rider should make these modifications at his own risk. Additionally these
mods may impact the OEM or aftermarket warranties, and each rider should consult your
dealer or service provider before making them and a rider performs them at his own risk.

Prepared by Taco Moto Co

support@tacomoto.co
725-273-7882

www.tacomoto.co
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