GASGAS DUAL-SPORT PROJECT THAT’S EASY ON THE EYES – SEPTEMBER 2025 ISSUE

The dual-sport world is on fire right now, and the aftermarket options available are mind-blowing. The Austrian brands of GasGas, KTM and Husqvarna are now offering OEM-branded items for their dual-sport lineup just like they do for their competition machines. Jeremy Scism, owner of AEO Powersports, is an enthusiast for anything on two wheels and pretty much up for anything. We decided to team up with the entire AEO crew to see if it was possible to build an off-road-worthy GasGas dual-sport machine using items available from their parts catalog.  

The crew at Decal Works gave our build a race-inspired look with some custom graphics.

TIME TO SHOP

Let’s be honest, the dual-sport machines available today are way better than what was on showroom floors a decade ago, and it wouldn’t be going out on a limb to say that we have KTM to thank for that. Pierer Mobility AG, the Austrian manufacturer that now owns GasGas and Husqvarna, pushed the limits of what was considered normal in the dual-sport segment, resulting in major advancements. Today, the manufacturer’s dual-sport models not only share a bloodline with the competition models in some cases, but they are extremely hard to tell apart. 

Like we mentioned before, GasGas, just like its sister brands KTM and Husqvarna, offers a complete line of aftermarket accessories that are purpose-built for their models and feature brand-specific coloring while providing performance upgrades as well. For our ES500 project we concentrated heavily on products that provided upgrades in the overall rider-comfort department, and no, we aren’t talking about making it “grandpa’s pavement princess”! We were thinking more along the lines of Justin Barcia’s professional race bike with factory upgrades. 

The ES500 uses WP Suspension components that can be upgraded internally, but they can also be completely replaced and upgraded to components actually used by Barcia and the factory GasGas race team. Up front the OEM fork was replaced with WP Pro components, the XACT Pro fork features a closed-cartridge system that uses cone-valve technology with SKF seals internally, and they come ready to bolt on with a customer-specific spring-rate and internal-valving setup with no modifications required by the end user. 

Test rider Pete Murray felt right at home aboard our GasGas ES500 project. He owns a similar KTM model.

We also replaced the OEM GasGas triple clamp with a CNC-machined aluminum split-design clamp system that offers an offset adjustment between 20mm and 22mm with a high-gloss red-anodized finish. The ES500 uses the same rear-suspension linkage as the competition models, so we switched out the complete rear shock with their XACT Pro 8950 rear shock that, just like the fork, comes internally valved and sprung specifically for the end user’s weight, skill level, and type of riding. 

We are all about being off-road, and the stock ES500 comes with more of a on-road-targeted Continental tire, so we decided to upgrade the complete wheel system. The new wheels feature black D.I.D Dirt Star rims, CNC-machined hubs that are anodized red to match the triple clamp perfectly, black spokes and anodized red spoke nipples. It’s got looks and performance all in one. 

The WP Suspension upgrades make a huge difference to the overall handling of this build, and if you have the money to spend, we highly recommend it.

We wanted a more off-road-worthy tire but still wanted to be legal for on-road use, so we wrapped the new wheels in Dunlop’s Enduro EN51 that is Department of Transportation (DOT) legal. We reused the OEM brake rotors. They are made by Braking and added a Supersprox Stealth rear sprocket that features steel teeth for long life and an aluminum center for reduced weight.

Protection was also important on this build, so we added it in very key areas for the rider and the machine. For off-road, handguards are a must; although, the stock models don’t come with them, so GasGas offers versions of the handguards that come standard on KTM and Husqvarna dual-sport models. While installing the handguards, we also put on some red-anodized ASV levers. The full-coverage skid plate protects the engine cases and frame rails from major damage, while the aluminum rear disc guard and carbon fiber rear caliper cover help protect the braking system.

The only performance product on this build related to engine performance came in the form of a slip-on exhaust system. FMF’s Q4 muffler is constructed of high-strength aluminum, has a low sound note and is 50-state legal for use.

THE HAUL

The 2025 GasGas ES500 is one of the better dual-sport platforms on the market today. Something to keep in mind when making upgrades is to keep it simple, so for the average rider, a few targeted changes might be all that is needed. We sort of took that approach on this build, at least compared to some of our prior projects.

The Q4 from FMF adds some performance, bling and is lighter than the OEM muffler.

Although we didn’t do any major engine performance modifications, we are happy with the way our ES500 performs, and the suspension upgrades are amazing. This dual-sport build is highly capable of handling any obstacle on the trail or any motocross track for that matter. We did find something on this build that was not universally liked by all our test riders, which is that the tall seat option is only recommended for riders north of 6 feet tall.

If you’re looking for a dual-sport, the GasGas ES500 is a good option and makes a great platform for building something custom without leaving the comfort of your local dealer, just like we did with the AEO Powersports crew. 

www.globalmotohub.com