BIKERELIABILITY Reg check
League table/ KTM/520 EXC
Model report · 2005–2025

Data as of: DVSA MOT results to 2025

KTM 520 EXC

520cc Petrol Class 2
#3734 of 5428 overall #167 of 230 KTMs #2373 of 2788 other bikes
79.2%
first-time pass rate
11.1%
failed outright
2,549
median miles at test
727
MOT tests, 2005–2025
-6.4pp
vs expected · age & mileage

The pass rate is the MOT first-time pass: a roadworthiness check of the items an MOT covers (brakes, lights, tyres, steering, structure, emissions), not a full mechanical inspection of engine or gearbox internals. It is a reliability signal, not a complete measure of mechanical reliability. What this measures.

“vs expected” adjusts for age, mileage and test class, so a cherished classic and a hard-used commuter are compared fairly. How this works.

Pass rate over time

first-time pass rate by test year · 2006–2016

The 520 EXC's first-time pass rate has fallen 6.2 points since 2006, 88.0% to 81.8%.

63%78%93%2006: 88.0% pass (75 tests)2007: 75.7% pass (74 tests)2008: 77.6% pass (58 tests)2009: 76.0% pass (50 tests)2010: 68.1% pass (47 tests)2011: 82.6% pass (46 tests)2012: 75.6% pass (45 tests)2013: 85.4% pass (48 tests)2014: 67.6% pass (34 tests)2015: 76.7% pass (30 tests)2016: 81.8% pass (33 tests)20062016

What fails on a 520 EXC

failure defects by component group · advisories excluded
Component group Share of defects Defects % of defects vs all bikes
lighting and signalling
81 35.7 1.5×
steering and suspension
46 20.3 1.3×
tyres and wheels
24 10.6 1.4×
reg plates and vin
23 10.1 4.1×
lamps and reflectors
16 7 0.6×
brakes
13 5.7 0.4×
suspension
8 3.5 0.9×
drive system
8 3.5 1.1×
wheels
5 2.2 4.6×
fuel and exhaust
3 1.3 0.5×

Defects recorded against failed normal tests, 2005–2025, grouped by DVSA inspection section. One test can record multiple defects. "vs all bikes" is how often this model's tests record a defect in the group, as a multiple of the all-bike rate.

How rivals compare

same type, similar capacity, high test volume

On first-time pass rate the 520 EXC beats 2 of its 4 closest rivals (KAWASAKI ZX-6R, SUZUKI GSF600, YAMAHA FZS600).

KAWASAKI ZX-6R 78.1% pass · 174k tests Compare head-to-head →
SUZUKI GSF600 77.3% pass · 143k tests Compare head-to-head →
YAMAHA FZS600 82.6% pass · 137k tests Compare head-to-head →
SUZUKI SV650S 80.6% pass · 84.6k tests Compare head-to-head →

Rivals share this bike's type and sit within ±30% of its engine capacity, ≥ 5,000 tests. Card colour = better/worse first-time pass rate than the 520 EXC.

Compare with any bike

rival not listed above? pick any model to see it head-to-head with the 520 Exc

More KTM models

other KTM bikes ranked by MOT pass rate
KTM 950 85.0% pass · 9,802 tests
KTM 125 71.0% pass · 9,690 tests
KTM 640 LC4-E 80.6% pass · 8,115 tests
KTM 450 EXC 76.4% pass · 7,579 tests
KTM 250 EXC 75.2% pass · 6,322 tests
KTM SUPER DUKE 990 86.7% pass · 6,217 tests

See all KTM models →

Pass rate by registration year

how each model-year cohort fares · registration year from first use date

Highest pass rate: 2001 (79.9%). Lowest: 2003 (74.0%). Every 520 Exc year compared →

73%77%81%2000: 77.8% pass (81 tests)2001: 79.9% pass (184 tests)2002: 78.7% pass (357 tests)2003: 74.0% pass (73 tests)200020022003

First-time pass rate by the year each bike was first registered (cohorts with ≥ 50 tests). Older cohorts are survivors: the worst examples have already left the road, which tends to lift the earliest years.

KTM 520 EXC FAQ

answers computed from the data above · terms in the glossary

Is the KTM 520 EXC reliable?

The KTM 520 EXC is less reliable than average for its class: 79.2% of its 727 MOT tests (2005–2025) passed first time, against a class average of 84.9%. That ranks it #3734 of 5428 models.

What does a 520 EXC fail its MOT on most?

lighting and signalling: 36% of all defects recorded against failed 520 EXC tests.

What is the best year of 520 EXC to buy used?

By first-time pass rate, 2001-registered examples do best (79.9%) and 2003 worst (74.0%). Condition and history still trump the year.

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