Adventurization of my Husqvarna TE511

Discussion in 'Thumpers' started by blaster11, Jun 23, 2013.

  1. blaster11

    blaster11 Challenge X-cepted

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    So the adventurization of my TE511 begins. Some say that the bike is just a dirt bike with tags....they may be right but I think it can be more....way more. So as I build it I will post the updates and changes...the good, bad, and the ugly of the build and the shortcomings of the bike if any. So what's my goal.....Minimum 200 mile fuel range, comfortable seat, and able to haul my camping gear and miscellaneous other stuff for up to a short multi week adventure. I am sure I will have more requirements as I really sit down and work through the details but these will do for a start.

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    Check back to this post regularly as this is where I will post updates to my plan and also which post you can go to for each upgrade.

    First upgrade is the pegs or should I say peg extensions. Since my foot is still pretty screwed up from last years incident I figured that a large platform on which to stand would be a good investment. So I got a hold of Zip Ty racing and placed an order for their peg extensions, they seem to be a leader in aftermarket parts for the Husky.
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    These should make life pretty good!

    So if you remember back a couple of years ago Bill Conger, an instructor from the BMW off road school, attempted Dakar but it didn't work out so well. In the process of the build of his TE449 he did quite a few things which I thought were pretty good so I took note and waited for the day I got my own TE.

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    One of the things I worry about is that Husky parts may become difficult to locate or that what little aftermarket there is may dry up so some parts may be purchased first just so that when they dry up I already have them, which is the case with my next part. An adapter for an external oil cooler from Zip Ty racing.

    Upgrade #2, the way I figure it cooler oil is happy oil, to a certain point, and more volume is good as well...especially for the long hauls, so I bought the part that I thought may be hard to come by and the more generic parts, i.e., oil cooler and lines, I will pick up a bit latter as time and $$ permit. The bonus is that the kit comes with a reusable filter so if you are out somewhere and flood the bike out, filter replacement won't be an issue, just change the oil and clean filter and carry on. Pretty nice piece!
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    #1
  2. blaster11

    blaster11 Challenge X-cepted

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    Since this bike on a good day only has about 165 watts of available power of which probably 1/2 or more of that is needed to run the bike. I realized that since I wouldn't be able to run a heated jacket liner, what was next most important thing to keep warm....that would have to be my hands. So I found a guy in the flea market selling a set of heated grips which should make life a bit nicer when the cooler temps roll around....I will install them later this year.
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    #2
  3. markusarealuis

    markusarealuis Been here awhile

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    Man that oil cooler looks like a killer gatling gun!:lurk[​IMG]
    I really can't wait to watch this thing develop!!
    #3
  4. markusarealuis

    markusarealuis Been here awhile

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    I think you should add one of these to your adventure bike.[​IMG]
    #4
  5. blaster11

    blaster11 Challenge X-cepted

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    Looks pretty nice, who makes it and how does it mount?
    #5
  6. blaster11

    blaster11 Challenge X-cepted

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    So the latest is to fix the auto retracting side stand. At first I found it entertaining but it quickly became irritating so with a quick spin of the Dremel with a cutoff wheel I removed the nub which makes it auto retract....back to a normal kick stand. :clap
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    Sorry I didn't get a picture while it was still attached.

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    All good now! :D
    #6
  7. blaster11

    blaster11 Challenge X-cepted

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    So one of the other things which is not only really irritating but also dangerous as hell is the problem known as "Flameouts". As I understand it it is due to an extremely lean fuel mixture which allows them to get past emissions but it stalls out at inopportune times, like pulling out in traffic. :eek1
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    So take off the seat and then you will see the computer which is held on with two rubber insulators, one on each side. Use a suitable tool and free the computer from the isolators.
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    Under the computer you will find two plugs, the smaller one is the one needed for the power up function.
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    Remove the cap and you will find two open pins, sorry I didn't get the picture without the jumper. I tried first with multi conductor wire but it kept fraying and was too big as well. I had a few pieces of solid conductor phone wire laying around so I made a short jumper and installed it.
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    I then reinstalled the original cap and put the connectors back where I found them and reinstalled the computer back from where it came.
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    This it what it looks like now on the odometer, it's hard to read but the screen says "Race map II" after installing the jumper. This should richen up the mixture a bit and stop the "flameouts"....hopefully. I haven't had a chance to ride it yet.
    #7
  8. markusarealuis

    markusarealuis Been here awhile

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    This was very helpful!! I did pull that last night and there is definitely not a "jumper" wire in mine. Also, have you ridden your bike since the "jumper" was installed? I have never experienced the "flameout" problem, and mine runs pretty smooth. Although it does lack any significant power.
    #8
  9. blaster11

    blaster11 Challenge X-cepted

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    Thanks...I am glad you found it helpful!!! I haven't had time to ride it yet as I have been pretty busy. Apparently the jumper along with removing the Cat makes a pretty significant improvement besides not burning your leg off just sitting still. If I get time this week the plan is to decat it as well. :evil
    #9
  10. LukasM

    LukasM Long timer

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    How long have you had the TE for, and how many miles of dual sporting have you done on it?

    Unlike it's big brother 610/630, the smaller Huskies are all known for their notoriously narrow gearboxes which suck for mixed slow and fast riding... :cry
    #10
  11. blaster11

    blaster11 Challenge X-cepted

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    About 2 months now and probably close to 500 miles of dual sporting. Definitely close ratio on the gearbox which has taken some getting used to. Actually my biggest complaint other than the seat is how twitchy the throttle is, I find it hard to regulate it as it is either on or off which is making it hard for me to be smooth on the trails.
    #11
  12. tokyoklahoma

    tokyoklahoma 75%has been 25%wanabe

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    #12
  13. blaster11

    blaster11 Challenge X-cepted

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    That is high on the list right now but my DRZ is down so I thought I would wait a bit so I wasn't without a bike. The ECU reflash seems like the way to unleash the bike along with the decat.
    #13
  14. dirtydeeds

    dirtydeeds I'm alive.

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    One of the best mods that I did on my ktm was a tool box built into the skid plate. I'll be making another for my Husky when I get a chance. Something to think about if you want to do week+ trips.
    #14
  15. blaster11

    blaster11 Challenge X-cepted

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    Good thought, I will keep that in mind.
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  16. blaster11

    blaster11 Challenge X-cepted

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    Not really a big deal to most but the gas cap on this thing is a real Bitch to take off and putting it back on usually took several iterations because it wanted to cross thread itself. Oh and if you didn't Grrrrrr it down tight it would leak. So the guys over on Cafe Husky told me about a factory Husky gas cap which was aluminum and would solve my problems....and it does and it is a nice looking piece to boot.
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    Stock POS
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    Notice how it's warped.
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    Just remove the gasket from the stock cap and install it on the new shiny cap and install....done! It screws on as a gas cap should now. :D
    In case you were wondering where I got the cap.
    http://www.halls-cycles.com/default.asp?page=xstore&keyword=8000H4069&submit1=Search
    #16
  17. blaster11

    blaster11 Challenge X-cepted

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    So if you are going to be out and about, at some point are going to be out of view of your bike. Well the way the bike comes you may not feel comfortable considering that it doesn't even have an ignition switch.....that's right no ignition switch! :eek1 Just jump on, pull in the clutch and push the start button and you are off and riding. So that's where Sicass racing comes in as they sell a plug-n-play ignition switch which plugs right in to your wiring harness.

    You can mount the switch one of two ways, either use the mount for a nonexistent switch which comes on the bike as I did.
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    Or this mount which can be bolted to the forks or some other suitable location.
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    The wiring harness is located behind the head light assembly so you will need to remove the four screws which hold on the fender and one up top below the dash cluster. This will allow you to drop the fender/light assemble out of the way so you can plug in the harness.
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    Four fender bolts
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    Top bolt below the gauge cluster which will need to be removed as well.
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    Here is the harness all plugged up and ready for use. I now have a little piece of mind when I walk away from the bike. :D
    #17
  18. AustinJake

    AustinJake DR650 - Versys

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    I was gonna do the same thing with my 2010 TE450, turns out, all I did was turn a 250lb sweetie into a 315lb cow. And the increased weight DOES hamper the good handling, the bike was just not designed to weigh so much. I get 32 mpg with a rich, great running program, so to get a 200 mile range, I would need a 7 gallon tank. The bike DOES serve as a great dual sport, and I've done some wonderful multi-day rides (with daily return to motels) in Colorado and New Mexico, the bike has almost 15000 miles on it, but it just is not the platform for loading down as an adventure bike.

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    #18
  19. blaster11

    blaster11 Challenge X-cepted

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    The real question is do you start with a heavy bike and make it heavier or start with a light bike and build what YOU want. I already have heavy Adventure bikes so this will have to fill the task of mid weight Adventure bike when loaded. I am not a racer so adding weight to the bike really doesn't bother me all that much and bottom line is most of the stuff won't even be on the bike the majority of the time when riding trails. Right now the bike is getting about 50MPG so all I really need is about 2 to 3 gallons extra to meet my goal with some cushion. The goals for the bike aren't really all that lofty so this will most likely be a pretty easy build....but only time will tell. :wink:
    #19
  20. markusarealuis

    markusarealuis Been here awhile

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    I think the bike might make an excellent candidate for an adventure bike. I had the same plan when I bought mine (2013 Te449). I am cheering you on:clap

    Mine gets around 42-45 mpg in stock form - no power adjustment yet:evil! I want to see how this develops before I make any changes.
    #20