Husaberg '09 FE570 rallye bike build

Discussion in 'Australia' started by SafariBerg, Dec 19, 2008.

  1. InertiaDRZ400

    InertiaDRZ400 AusSafari Addict

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    Seems like a nice blue KTM you have there!

    That is a nice bike but!
    #21
  2. Mark950

    Mark950 Been here awhile

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    mmmm this will be interesting....subscribed.
    #22
  3. Rusberg

    Rusberg Adventurer

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    Gee Gazza looks like the wait was worth it. Look forward to seeing your project unfold. I am waiting patiently for mine due at dealers in Vic 23/12
    I am interested to know what the standard gearing it came with and what you will use and the 4l tank project.
    #23
  4. SafariBerg

    SafariBerg Oz Safari Addict

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    The standard gearing is 13:52

    I have seen comments from guys in the States and EU saying they are using 13:50 etc

    Not sure what we will use yet

    On the FE650s' we run 16:46 while stock is 15:45

    So maybe around 14:52 or 51

    But the primaries on the 570 are a lot higher geared to go for such a low final as standard.

    29:78 on the 650 compared to 33:76 on the 570

    Interestingly the KTM 530EXC is the same at 33:76 but runs 14:52 as the standard gearing :dunno

    I'm away for most of Jan so wont get onto the 4L sub-tank until Feb
    #24
  5. clarky

    clarky 05' 640 Adv

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    Looks really great Garry, but why are they 12kg heavier than the 650? 114kg against 102. They certainly look more compact and with a smaller donk I would have thought they would be lighter :huh

    Looking forward to hearing how it rides!!

    cheers
    #25
  6. SafariBerg

    SafariBerg Oz Safari Addict

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    the 650's claimed dry weigth is 109kg - not sure why the extra 5 kgs on the new ones

    they feel a little heavier when pushing it around, but not much, similar to a 530

    But riding it feels like a 250F, so much lighter and easier handling,

    Effortless ! is the key word that always comes to me
    #26
  7. LC8TY

    LC8TY must......find........fuel

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    I'll be watching this rally bike build after todays events.

    I'm in Perth and went to Wanneroo MC today to check out the new Bergs.

    I took a 450 for a test ride around the streets, no dirt unfortunately. First impression when throwing a leg over is that it feels like any other KTM 450/525.

    The big diference is the motor, it has way more torque and power than any other stock standard 450 I've ridden. I can only imagine what the 570 pulls like.

    Brakes, suspension and ergos feel good and I can see a 570 Berg in my shed in the near future.:evil
    #27
  8. stormsearcher

    stormsearcher Been here awhile

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    hey berg,where can i find a rs concepts fairing pls?
    #28
  9. SafariBerg

    SafariBerg Oz Safari Addict

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    PM Mudguts he has copies you could get, he is in Melbourne

    alos pm CPWSAFARI<SCRIPT type=text/javascript> vbmenu_register("postmenu_8466441", true); </SCRIPT> he has them as well, he is in Perth
    #29
  10. hicksamunga

    hicksamunga Adventurer

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    any updates?:ear
    #30
  11. JayBo1

    JayBo1 Long timer

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    I'll be building one of these for the '09 Oz Safari! Latest offering from Mecasystem to compete with the RS Concepts kit. Uses standard Hardparts main fuel tank and standard Mecasystem fairing nose cone, vertical twin headlights and nav tower.

    [​IMG][/IMG]

    Yummy.
    #31
  12. InertiaDRZ400

    InertiaDRZ400 AusSafari Addict

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    Jaybo1, If you do find some radiator guards that fit with the big tank, then let me no! The force ones dont fit, and the rest look rubbish!
    #32
  13. hicksamunga

    hicksamunga Adventurer

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    how's the build going?:ear
    #33
  14. SafariBerg

    SafariBerg Oz Safari Addict

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    After getting the bikes ready for both Condo 750 and the Yilgarn Rallye, work started on the Safari set up in May. The basic approach has been to keep it simple, light, durable, quickly repairable and use items that are known and easy to get spares for etc.

    The team is running six '09 FE570's and two '08 FE650's for the Safari this year.

    The 650's are well proven over the '08 & '07 Safari's as being very fast and bullet proof. No issues of any kind, just routine oil & filters etc and the best power to weight in the field bar none.

    [​IMG]

    The 570's have had some prelim runs at both Condo and Yilgarn.

    [​IMG]

    Overall they have performed very well but with a couple of niggles with the injectors not liking contaminated fuel :cry
    [​IMG]



    The 570's lack the grunt of the 650's and some of the speed but handle heaps better and are much easier to ride, very low energy input needed from the rider, which is great for an endurance rallye event.

    BUT for the Safari they are still unproven so it will be a test bed year. A test bed also for Dakar with a 570 planned to be heading to Argentina come January 2010 :evil


    A recent session on the dyno with both a 570 and 650 back to back had the 570 putting out a healthy 55 rwhp and the 650 a stonking 60 rwhp. The big difference is the curve. In 4th gear the 650 is pulling peak power all the way from 80kph to 140kph............just the main speed zones used on the Safari :evil . Where as the 570 had a good steady smooth climb to peak power at about 120kph in 4th.

    So the 650 has lots of grunt that pulls from low all the way through the rev range, a very big flat plateau of power. The 570 a typical curve up to a peak.

    Just to put some of this in perspective on the same dyno a 530 EXC-R gets 49-50 rwhp and a 450 about 44-45 rwhp. Also a ridgey dige 690RR rally on the same dyno put out the same rwhp as the 650 :deal :evil :evil , but again had a bit better power curve and torque. BUT this is lost with the almost 50kg extra lard it has to lug around :lol3

    It's still hard to beat the FE650 as a rallye bike platform for outright speed and point & shoot, it will out accelerate all others. Plus a bit of blue-printing and special attention to the lead 650 this year (the bikes used for the last 2 years have been dead stock) will give it around 65 rwhp :gdog and it will be the fastest bike in the field bar none :nod :deal

    on to the build

    The nice shiney new 570's quickly go from
    [​IMG]

    to
    [​IMG]

    to
    [​IMG]

    and then before they even turn a wheel in anger to
    [​IMG]



    Up front on the nav gear side it is the usual MD Roadbook with ICO odo's. Inside the MD is a strip of LED's to shed light for the pre-dawn starts or a late return to the bivouac.

    [​IMG]

    Some riders are running dual ICO's. The benefits are a backup should an issue occur, usually a broken sensor cable. Also can have both distance and speed or time readouts showing at the same time, or split distances re fuel use and stage distance or similar. The ICO's used are the VRL which has in built lighting.


    [​IMG]

    Others are running single ICO and the OEM speedo with the KTM remote thumb switch.

    [​IMG]

    To make room for the odo thumb switches the indicator/kill switch has been moved to the clutch hose, or on some bikes to the barkbuster plastic guard. The kill switch get used a lot, and the horn sometimes, though the Safari Supp Regs requires indicators as well.

    [​IMG]

    [​IMG]

    The KTM hardparts roadbook frame works well, with the MD & ICO alloy mount bracket courtesy of CPW Safari

    [​IMG]


    [​IMG]
    The rear suspension gets a spring upgrade from the stock 7.4 to 7.8, 8.0 or 8.2 depending on the riders weight and riding style.

    The stock exhaust is used on most bikes with the end cap mod which helps them breath better
    [​IMG]

    Though a couple of bikes are running the Akrapovic slip on
    [​IMG]

    Header heat sheild
    [​IMG]


    [​IMG]
    Berg hardparts case saver guard and 15T sprocket up front

    [​IMG]
    Flush mount LED blinkers courtesy of CPW Safari

    Underbar Scotts steering damper, though some not so tall riders have gone for the Scotts above the bars
    [​IMG]


    Going to give the new Ohlins SD2-MX steering damper a try on my bike and see how it compares to the well proven Scotts
    [​IMG]

    [​IMG]



    [​IMG]
    The ADR start/kill switch block is replaced with the euro model start button, simpler, not able to be accidently turned off by bumping the kill or kill left on etc


    Well designed Force Accessories 2L Safari bashplate to carry the required emergency water down low and to protect the engine, it has some winsg to cover the radiator hoses etc as well. Force are also making up a 3L version for Dakar use to meet the different regs.
    [​IMG]


    Berg hardparts Stealth rear sprocket, either 50T, 49T or 48T depending on the rider's likely speed and/or preferences
    [​IMG]

    [​IMG]


    Berg hardparts neoprene fork seal savers to keep it all happy
    [​IMG]



    hmmm the head off to get some magic done to it by a well respected flow guru. Substantial gains in torque and some extra power all acoss the rev range wil help Coak keep the 650 boys honest :evil

    [​IMG]


    Note the manual chain adjuster..........less risk than the stock hydrualic one.

    [​IMG]

    Berg hardparts plastic frame protectors
    [​IMG]
    #34
  15. LC8TY

    LC8TY must......find........fuel

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    Very nice Mr Berg, but what about fuel? hows is the Safari tank development going.

    Is Brandons bike the only one running the low slung rallye pipe?
    #35
  16. SafariBerg

    SafariBerg Oz Safari Addict

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    The Safari tanks are now close to final production, I should have the first one out the molds next week.

    It will be a 12L front tank that adds to the existing stock 8.5L tank using the existing fuel pump system etc.


    And a 8L rear saddle tank like the Honda one Grabbo uses

    [​IMG]

    but still retaining existing up swept original exhaust & muffler arrangement


    Brandon being the macho boy he is has opted for the 650 for the Safari :evil , he is physically a big strong guy and likes the V8 grunt :gdog
    #36
  17. atgreg

    atgreg Africatwinarama

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    very, very nice !!!
    #37
  18. hicksamunga

    hicksamunga Adventurer

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    +1

    :clap:clap:clap
    #38
  19. ChrisCrossed

    ChrisCrossed Now sans KLX...

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    Tell Brandon from me that the 650s are the go for big strong macho boys :wink:

    Top work there gary. You've already cost me money. An MD made it's way into my letter box recently.
    #39
  20. Sylvia

    Sylvia vir sapit qui pauca loqui

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    Berg porn

    :tb:tb

    love your work Gary...
    #40