Adventure riders often dream of a single machine that can do it all: light enough for technical trails, comfortable enough for long days in the saddle, and capable of tackling everything from rally stages to weekend exploration. Former enduro champion and “big bike whisperer” Chris Birch believes he’s come close to building that elusive “Unicorn Bike,” unveiling his version of the ultimate all‑rounder.

Birch’s starting point was the KTM 500 EXC-F, a machine already respected for its lightweight agility and off‑road pedigree. “Adding a bit of Rally and a splash of Hard Enduro,. I wanted to make it comfortable to ride all day and to cover long distances, without ever compromising performance,” says Chris.

Fuel range was one of the first challenges Birch tackled. The stock EXC tank is fine for short enduro loops, but it falls short when you’re covering long distances across remote terrain. To solve this, Birch fitted twin fuel tanks modeled after those found on the KTM 450 Rally Replica bike, adapted to fit the 500 EXC-F. The design not only extends the bike’s reach but also carries the fuel low, helping maintain nimble handling while delivering the range required for multi‑day adventures.

The kit also includes a robust skid plate to protect the underside of the machine, ensuring durability in demanding conditions. And perhaps most exciting for riders, Birch notes that the complete twin tank setup will soon be available to the public. 

Navigation and cockpit setup also received an overhaul. Birch added a lightweight rally tower from Aurora that houses GPS, roadbook, and digital instruments, transforming the EXC into a machine capable of rally navigation while still being manageable in tight singletrack. The tower integrates upgraded LED lighting, giving the bike the ability to tackle night stages or poor visibility conditions during adventures.

To boost its ability to tackle gnarly terrain, WP Pro suspension components front and rear were set up for Chris by Solid Performance. An XRC anti-fatique handlebar mount was added to help absorb the impact forces acting on the bars, as well as dampen engine and chassis vibrations. An R&Duro Throttle Housing delivers smoother throttle action, plus heavy-duty R&Duro levers and DoubleTake mirrors provide additional durability against the inevitable knocks of enduro riding. 

Chris’ 500 is also equipped with the TACS‑PRO Racing Tire Air Control System— a relatively new innovation developed for hard enduro and rally competition. The system integrates a compact pump and control unit that allows automated inflation and deflation of the rear tire while riding. This eliminates the compromise of running a single tire pressure all day, giving Birch the ability to fine‑tune grip and performance as terrain changes.

Versatility of the bike was taken up several notches by the TSP ERM (ECU Reflash Module) device fitted on the handlebars. It’s essentially a plug‑in ECU tuning tool that allows riders to reprogram and adjust the stock mapping and more on the fly. Ignition timing, engine braking and traction control are only a few of the performance outputs Chris can tailor to his riding style and terrain. “It’s incredible…I’m only scratching the surface of what this can do,” he explains. The setup is paired with an Akrapovic exhaust while the whole machine rolls on Mitas Terraforce rubber.

For those long days in the saddle, Birch fitted a more comfortable flat seat that will still allow him to move freely on demanding off-road terrain. A ribbed section near the front of the seat helps with grip and prevents unwanted sliding.

Birch emphasizes that the bike is never truly finished. The KTM 500 EXC-F platform allows for continuous refinement, and he continues to experiment with setups that balance performance, durability, and rider comfort. Still, he’s “really stoked with how it came out” and believes it represents a strong step toward the mythical all‑rounder. Check out Chris’ build video above and let us know your thoughts.

Photos by Chris Birch