ER5 is built on the 2026 KTM 390 Adventure R, the off-road-serious version of KTM's lightweight adventure platform. The R-spec comes from the factory with 21-inch front and 18-inch rear spoked wheels, long-travel WP APEX suspension with around 230mm of travel front and rear, 10.7 inches of ground clearance, and a tall aggressive stance built for riders who actually leave the pavement.

The engine is a 399cc liquid-cooled single making 44.4 hp, paired with a 6-speed gearbox, slipper clutch, and Bosch switchable cornering ABS with a dedicated off-road mode. It weighs just 364 lbs dry, over a hundred pounds less than most flagship adventure bikes.

This isn't a street bike that can handle some dirt. It's a purpose-built off-road machine that happens to be street legal. That's the foundation ER5 is built on.

Key specs:

• Engine: 399cc liquid-cooled single, 44.4 hp
• Suspension: WP APEX long-travel, ~230mm front and rear
• Wheels: 21" front / 18" rear spoked
• Weight: 364 lbs dry / 388 lbs wet
• Seat height: 34.3" / Ground clearance: 10.7"
• Fuel capacity: 3.8 gallons
• ABS: Bosch switchable cornering ABS with off-road mode

The 2026 KTM 390 Adventure R is one of the most capable lightweight adventure bikes ever built from the factory. It's also missing about $5,000 worth of work.

Months of research, parts ordered from around the world, a full week in the shop building and fitting, and a complete weekend of real-world testing across Colorado's backcountry. That's what goes into an Expedition Ranch build. Every upgrade was chosen to solve a specific problem. Nothing is here for looks, nothing is redundant, and nothing fights the bike's character.

The goal wasn't to turn the 390 R into something it isn't. It was to make it everything it already wants to be: trail-hardened, travel-ready, properly lit, and tuned to actually perform. The result is a bike that's protected enough to ride without fear, capable enough to go where the trails go, and kitted out to keep going for days.

This is the ultralight adventure bike people said didn't exist. We built it.

Total build value: $14,145

Upgrades: 25 parts / ~$4,974 retail value

Sponsors: B&B Offroad Engineering · Cyclops Adventure Sports · Adventure Tech Pro · Motion Factory Racing

Two modifications. Both change how the bike feels every single second you're riding it.

POWERTRONIC FUEL X PRO + TUNER
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The stock 390 R runs lean in places for emissions compliance. You feel it as a flat spot or a stumble coming off slow corners. The FuelX Pro+ is a plug-in fuel optimizer that wires inline between the bike's O2 sensor and ECU, continuously monitoring and retuning the air/fuel mixture in real time for your riding style, altitude, temperature, and any bolt-on mods. The result is cleaner throttle response and stronger, more usable power right where you ride, off idle and through the midrange. It ships with a handlebar-mounted switch and 10 selectable maps you can change on the fly. Fully plug-and-play, no permanent ECU changes, completely reversible.

14 TOOTH FRONT SPROCKET
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One tooth down from the stock 15T front sprocket. That single change lowers the overall gearing enough to transform how the bike behaves on trail. More low-end pull for technical climbs, better control at slow speeds, and less stalling in tight sections. You give up a little top-end speed you were never going to use off-road anyway. It's the cheapest, highest-impact trail mod on this entire build.

Six parts working together to make ER5 droppable, rideable, and protected from nose to tail. On a bike built for technical terrain, tip-overs and rock strikes aren't accidents waiting to happen. They're part of riding. This is the hardware that keeps a bad moment from becoming a tow-out or a repair bill.

TUSK QUIET GLIDE SKID PLATE
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Full-coverage underbelly protection for the engine cases, water pump, and frame rails. Built from 3/16" aluminum topped with a 1/4" UHMW polymer overlay. The polymer dampens the ring and buzz of bare metal, absorbs rock hits, and lets the bike glide over obstacles instead of hanging up on them. Solves the single biggest vulnerability of a trail-ridden single: a cracked case miles from the trailhead.

TUSK CRASH BARS
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Frame-mounted engine guards that take the hit in a tip-over or low-speed crash, shielding the radiator, tank shrouds, and upper plastics from damage. They also double as the mounting point for the Cyclops auxiliary lights. On a bike built for the dirt, these aren't optional.

TUSK D-FLEX PRO HANDGUARDS
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Wrap-around guards that protect hands and levers from brush, roost, rocks, and wind. The tempered aluminum bar flexes on impact instead of snapping, and both the bar and the plastic shields are replaceable. Cold hands, snapped levers, and stinging knuckle hits on tight trail are all solved in one part.

B&B OFFROAD RADIATOR GUARD
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CNC-machined from 4mm marine-grade aluminum, this guard gives the radiator full frontal coverage against rocks, roost, and branch strikes. A punctured radiator ends a ride and can destroy the engine. On a liquid-cooled single this is mission-critical protection. Designed and manufactured in Australia by B&B Offroad Engineering specifically for the 390 Adventure R.

B&B OFFROAD HORN SHIELD
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The stock horn sits completely exposed and is one of the first things to get torn off or crushed in a fall. This bracket relocates and shields it, tidying up the front end and keeping it intact when the bike goes down.

B&B OFFROAD SPROCKET COVER
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A 4mm aluminum cover over the countershaft and sprocket area that keeps mud and debris out, helps contain the chain, and protects the cases. A small, inexpensive part that prevents an expensive, ride-ending failure.

MOTION FLEX-MOUNT ADVENTURE PEGS
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Oversized two-piece footpegs with a patented flex system that lets the platform rotate slightly fore and aft, tuned by selectable bushings for vibration damping and fatigue reduction. Off-road control comes through your feet. A bigger, better peg changes how the whole bike feels underneath you. ER5 runs the extra-wide Adventure platform, the size Motion recommends for ADV bikes.

Knowing where you are matters just as much as the bike underneath you. ER5 runs a dedicated navigation setup that works in the backcountry and survives the elements.

ADVENTURE TECH PRO RUGGED NAVIGATION TABLET
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A 7-inch 2600-nit daylight-readable touchscreen running Android 13. Run the apps you already trust like onX Offroad and Gaia GPS instead of being locked into one ecosystem. MIL-STD-810G rated for shock, vibration, water, dust, and temperatures down to -40 degrees. Built-in 4G LTE and a 7000mAh battery that runs for days off-grid. No more sacrificing your phone on the bars. Designed and assembled in the USA by Adventure Tech Pro out of Woodland Park, Colorado.

VANASCHE MOTORSPORTS GPS MOUNT
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A billet aluminum mount purpose-built for the 2025 and 2026 KTM 390 Adventure R. A cogged-tooth arm engages a pocketed base so it will not rotate under hard impacts or vibration. Cheap mounts let screens blur and shake loose. This one doesn't move.

ER5 goes from a bike with nowhere to put anything to a legitimate multi-day travel rig. The luggage system is built around a dedicated rack and panel setup that keeps bags secure, off the plastics, and away from the rear wheel.

B&B OFFROAD TAIL RACK
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A heavy-duty 5mm aluminum rear rack that bolts directly to the subframe using factory mounting points. It creates a strong flat platform for a top bag or duffel and serves as the backbone the entire luggage system hangs off. Stock tail sections aren't built to carry loaded weight off-road. This one is.

B&B OFFROAD SIDE LUGGAGE PANELS
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Aluminum panels that mount to the tail rack and give soft panniers a stable surface, keeping bags off the plastics and out of the rear wheel. They solve the two classic soft luggage failures: melted bags and wheel intrusion.

B&B OFFROAD STRAP STAX KIT
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Modular M6/M8 tie-down anchor points that give you purpose-built places to strap gear instead of improvising around the frame. CNC-machined corrosion-resistant alloy.

TUSK EXCURSION RACKLESS BAGS
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A rackless soft luggage system that carries multi-day gear low and centralized for better handling. Four nylon webbing straps let the whole setup come off the bike in seconds. Includes removable waterproof inner liners.

TUSK OLYMPUS TANK BAG
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Puts phone, wallet, snacks, and a map within reach without stopping. Includes a rain cover and quick-release buckles.

TUSK FENDER BAG
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A small front fender bag for tubes, tools, or tie-downs. Weight kept low and out of the way.

ER5 is built to be ridden at dawn, dusk, and after dark. The stock lighting is barely adequate for low-light riding. This setup fixes that from both ends of the bike.

CYCLOPS ARIES AUXILIARY LIGHTS
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A high-output LED auxiliary light set that transforms how far and how well you see at night and how well you are seen by others. American-made Cree LEDs in a compact CNC-machined 6061-T6 aluminum housing behind an unbreakable polycarbonate lens. IP67 waterproof and dustproof. Wires to the factory controls with no separate switch required. Includes safety-yellow lens inserts so you can run white or yellow depending on conditions. Cyclops has been the industry leader in ADV lighting since 2002.

CYCLOPS CRASH BAR LIGHT MOUNTS
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Aluminum clamp brackets that mount the Aries lights low and wide on the Tusk crash bars for the best possible spread and protection.

SKENE P3 TAIL LIGHTING SYSTEM
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A programmable auxiliary tail and brake light system that makes the rear of the bike far more visible to traffic. Features Skene's patented Conspicuity Flicker, which intensifies as a vehicle closes in from behind. Covers a roughly 180-degree viewing angle.

ER5 looks the part in every frame of footage and in person. The graphics and body work give it a distinct identity while adding real protection to the plastics underneath.

MOTO PRO GRAPHICS KIT
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A custom ER-liveried graphics kit in desert tan, black, and dark green. Officially KTM-licensed and produced by MotoProWorks on high-tack vinyl with an air-channel adhesive and protective over-laminate. Precision pre-cut to cover the tank panels, front fender, side fairings, rear panels, swingarms, tail section, and headlight mask. It doubles as a protective layer over the bodywork, not just a cosmetic upgrade.

B&B OFFROAD TIDY TAIL KIT
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A fender eliminator that cleans up the rear end, relocates the plate and lighting, and removes the long stock fender that flexes, catches, and cracks on the trail. Lighter, tougher, and better looking. Designed to work with the B&B tail rack and side luggage panels.

The right tire makes or breaks a do-everything adventure build. ER5 runs a dual-sport setup that handles the dirt without becoming a liability on the road.

TUSK D-SPORT ADVENTURE TIRES
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DOT-compliant dual-sport tires front and rear with an aggressive tread pattern for off-road grip and a compound tuned for long on-road wear. Tall knobbies deliver real bite in loose dirt, gravel, and mud while staying predictable on pavement. The right all-round footwear for a bike that goes everywhere.

The details that don't fit a single category but earn their place on the build.

DOUBLE TAKE ADVENTURE MIRRORS
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Folding mirrors on RAM-style ball joints that survive crashes, fold flat for tight trail, and pivot to any angle. The stock mirrors snap off in a tip-over. These are guaranteed against breakage. Sourced through Vanasche Motorsports.

TUSK KICKSTAND SPRING RELOCATION BRACKET
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A small steel bracket that moves the kickstand spring behind the stand, increasing tension and adding boot clearance. Keeps the stand locked firmly up so it won't drift down mid-ride and trip the kickstand safety sensor, which would cut power to the bike.

Entering is EASY... but knowing how to get the most entries... well that's what this section is for.

🎟️ QUICK ENTRIES: Quick entries are often the best deal on our site for the most entries!
🎟️ BUNDLES: Bundles are worth DOUBLE entries!
🎟️ BOOSTERS: Grab a Cart Booster to boost all the entries in your entire order!
🎟️ MEMBERS ONLY: Perks exclusive to members ➡️ Perks
🎟️ FREE BONUS ENTRIES: Spend $100 or more and receive 150 Bonus Entries! Spend $200 or more and get 300 Bonus Entries!

You can check your TOTAL ENTRIES in your cart before you check out!

BONUS PRIZE
There is one bonus prize for this giveaway. An ICECO APL20 portable refrigerator with a retail value of $559. Anyone who enters between July 3rd and August 9th can win the bonus prize and still be in for the Grand Prize!
BONUS PRIZE ANNOUNCED AUGUST 19TH!

GRAND PRIZE ER5
The 2026 KTM 390 Adventure R with an estimated build value of $14,145 closes on September 13th and is announced on September 23rd.

This is a fully built, trail-ready adventure machine and we wish you the best of luck!