The arrival of KTM’s 2025 390 Adventure R generated plenty of buzz among riders looking for a compact and manageable dirt-friendly adventurer, especially when considering its $7k introductory price. Building on the popularity of the original 390 Adventure, the new “R” variant brought rally-inspired ergonomics, upgraded suspension, smoother highway performance, and serious off-road intentions.

Yet as versatile as the 390 Adventure R is straight from the factory, there is room for improvement in areas like protection, ergonomics, engine performance and long‑distance comfort. That’s where accessory maker Black Dog Cycle Works stepped in with their latest project.

Known for transforming stock machines into expedition‑ready ADV bikes, BDCWs approach was to strengthen the bike in practical ways for dirt fans that want to push deeper into the backcountry: adding more robust armor for off‑road use, improving comfort for highway stretches, fitting soft luggage suitable for camping off the bike, and giving it some targeted mods to wake up the low‑to‑midrange torque for slower, technical trail riding where it’s sorely needed. Let’s take a closer look at the upgrades.

BDCW Ultimate Skid Plate

One of the first upgrades BDCW made to the 390 Adventure R was their iconic Ultimate Skid Plate. Unlike the stock option that bolts directly to the engine case, this plate mounts to the frame for maximum strength and impact dispersion. A rubber “Shok Blok” sits between the plate and engine to absorb hits, while the smooth, flat bottom lets it slide over obstacles without obstruction. Unlike the thin metal and plastic stock plate, the BDCW plate uses 3/16‑inch thick aluminum with steel brackets and a powder coat finish, while offering significantly more coverage on the sides and undercarriage. The design incorporates a “crush zone” to absorb impacts between the plate and vital components, while still maintaining good ground clearance. For riders pushing into rocky terrain, this is cheap insurance against catastrophic damage to the motor and exhaust. MSRP $435.00

Coober De‑Cat Header + LM ECU Programming Device

One of the 390 Adventure R’s weak points is its lack of torque at lower RPMs. To address this, BDCW installed Coober’s De‑Cat header pipe along with the LM ECU programming device. The cat‑delete frees up exhaust flow, while the ECU tuning keeps fueling optimized for performance and efficiency. The result is a noticeable bump in low‑to‑midrange torque, smoother throttle response, and a throatier exhaust note. On a short test ride, the difference was immediate: more grunt off idle and better rideability in slow, technical terrain, exactly where the stock 390 engine struggles. MSRP $699.99

Barkbusters Jet Handguards

Handguards are essential for serious off‑road travel, and BDCW installed Barkbusters Jet guards with a full wrap‑around alloy backbone, unlike the all-plastic stock units. These protect levers from breakage in tip‑overs and shield hands from brush, roost and wind. The kit is designed for 1‑1/8″ taper bars and the plastic shields are replaceable once they’ve been damaged or worn out. Lightweight but strong, they add durability without overcrowding the available space on the bars for attaching additional accessories. MSRP $120.00

DoubleTake 4.7″ Adventure Mirrors

Stock mirrors are notorious for shattering in a fall, so BDCW swapped them for DoubleTake Adventure Mirrors. Using RAM-style ball mounts and a 4.7″ stalk, they provide excellent rearward visibility on the highway yet can be quickly folded down when you reach the trail to avoid snagging on brush or breaking in a tip‑over. They also fold out of the way on impact and can be repositioned instantly after a crash, making them a practical upgrade for adventure riders who split time between pavement and trail. Made with super tough glass reinforced Zytel material, they are virtually indestructible and come with a lifetime warranty. MSRP $136.00

BDCW Traction Footpegs

Standing on the pegs is mandatory in technical terrain and the stock KTM units can feel inadequate for serious off‑road use, so BDCW developed their Traction Footpegs to give riders a larger, wider, more sure-footed platform. CNC‑machined from billet aluminum, they are both lightweight and extremely durable when clipping rocks and boulders on tight singletrack trails. The oversized design provides improved comfort and control, especially on long rides, while aggressive stainless steel traction teeth ensure boots stay planted in mud, sand, or wet conditions. MSRP $249.00

ProTaper Pastrana FMX Bend Bars

To improve ergonomics and durability, BDCW installed ProTaper Contour Pastrana bend handlebars. These 1‑1/8″ bars are strong, lightweight, and engineered to resist bending in a fall—a critical upgrade for riders tackling rugged terrain. The tall Pastrana bend improves rider posture when standing, reducing fatigue on long off‑road sections. Combined with other cockpit upgrades, they give the 390 Adventure R a more rally‑bike feel and better control in technical riding conditions. MSRP $99.99

BDCW Rear Rack

Adventure travel demands luggage capacity, and the 390 Adventure R’s stock setup is limited with no rear rack or anchor points for soft luggage. BDCW’s Rear Rack provides a sturdy, CNC‑machined aluminum platform with multiple tie‑down points for soft bags of all types, whether you are running a saddle bag system, large duffel or just a tool bag. It also comes pre-drilled for RotopaX containers if you want to haul extra fuel or water, which can be installed either lengthwise or across the bike. Powder‑coated for durability, the 12” x 12” platform integrates seamlessly with the back of the seat allowing you to optimize loads for better weight balance. Whether carrying camping gear, hotel essentials, firewood, or groceries for camp, the BDCW Rear Rack offers a secure, versatile platform that makes loading and unloading quick and hassle‑free. MSRP $259.00

Mosko Moto Gnome Tank Bag

Compact and functional, the Mosko Moto Gnome Tank Bag adds 5 liters of waterproof storage without cluttering the cockpit or interfering with body movement standing up on the trail. With a removable 1.5-liter hydration reservoir and quick‑release mounting, it’s perfect for essentials like snacks, tools, or electronics. Inside, multiple pockets and internal organization slots make it easy to separate tools, snacks, electronics, and documents. With its included water reservoir, riders can sip water without stopping and can avoid carrying extra weight on their back. On the outside, MOLLE panels allow for expansion or attaching accessories, while a rain cover ensures gear stays dry in heavy rain. For riders who dislike bulky tank bags, the Gnome strikes a balance: small enough to stay out of the way, yet packed with thoughtful features that make it indispensable for both day rides and extended ADV travel. MSRP $249.00

Mosko Moto Reckless 10 Saddlebags

For luggage, Black Dog’s owner Kurt Forgét wanted a minimalist setup that could handle lightweight camping or hotel travel. The Mosko Moto Reckless 10 was the perfect fit. With 10 liters of waterproof capacity in a rackless design, it keeps the bike nimble while still offering practical storage. Mounted directly to the rear rack and subframe, it contours to the bike, balances weight and avoids the girth of rack mounted bags, allowing you to squeeze through tight trees and weave around rocky outcrops much easier. The system is 100% waterproof, with two 5L dry bags that slide easily in and out of the harness—making it simple to carry essentials into a hotel room or tent once you arrive. On the underside, an EVA foam pad reduces chafe to the bike, protecting finishes. Built‑in straps allow riders to add a top bag for bigger trips, expanding capacity while keeping gear solidly mounted. MSRP $409.00

Rigid Industries 6‑Inch Lightbar Kit

Night riding is often unavoidable on multi‑day trips, and while the stock LED headlight is decent, it falls short of the powerful illumination an auxiliary light provides. BDCW added a Rigid Industries 6‑inch LED lightbar, available in both SAE‑approved and Pro versions. The SAE model allows you to legally run it at night on the road without blinding oncoming traffic, while the Pro light is simply too bright to use around traffic but for off‑road or backcountry riding it turns night into day. The unit tucks neatly under the headlight, keeping it protected from damage in a fall, and comes with an amber clip‑on lens that improves visibility in fog while also making the bike more noticeable to cars on the road. MSRP $421.00

Renazco Racing Custom Seat

Comfort is critical for long days, and the stock 390 Adventure R seat quickly becomes a limiting factor, as we found after a long ride from Los Angeles to Breckenridge, Colorado. Renazco Racing’s handcrafted custom seat solves that with wider perch, a plush suede cover and premium foam tailored to rider specs. Each seat is built to order, tailored to rider weight, height, and riding style. The result is a seat you can ride all day, whether tackling BDRs or commuting. It’s a subtle but essential upgrade that boosts the bike’s long‑distance capability. MSRP $400-$600

BDCW Throttle Control

Highway stretches can be punishing on a lightweight single, so BDCW added their mechanical Throttle Control to give the 390 Adventure R a cruise‑control‑like function. Simple, durable, and designed for real‑world ADV use, it locks the throttle in place to reduce wrist fatigue on long rides. When engaged, it applies light friction to hold the throttle open, yet still allows quick emergency roll‑offs when needed. While it’s a small upgrade, it makes a big difference in rider comfort, especially when covering long distances between trailheads. Please note the Throttle Control isn’t compatible with the stock KTM 390 Adventure R handlebars, but the upgrade does work with typical 1-⅛” fat bars like the upgraded ProTapers fitted on this bike. MSRP $160.00

Garmin Zumo XT GPS

Navigation is the final piece of the puzzle. The Garmin Zumo XT offers a glove‑friendly, ultra‑bright display with preloaded topo maps, satellite imagery, and off‑road routing. Rugged and waterproof, it’s built for motorcycle vibration and pairs with smartphones or inReach devices for added safety. For riders exploring remote areas, it ensures confidence to push deeper into the backcountry knowing you can find your way. MSRP $499.99

KTM 390 Adventure R Build Parts List

Author: Rob Dabney

Rob Dabney started a lifelong obsession with motorcycles at the age of 15 when he purchased his first bike – a 1982 Honda MB5. Through his 20’s and 30’s he competed in off-road desert races, including the Baja 250, 500 and 1000. Eventually, his proclivity for exploration led him to dual sport and adventure riding. Rob’s never-ending quest to discover what’s around the next bend has taken him on Adventures in Latin America, Africa, Europe, Asia, and throughout the American West. As a moto journalist, he enjoys inspiring others to seek adventure across horizons both near and far.