Husaberg '09 FE570 rallye bike build

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

  1. pete40

    pete40 Life Behind Bars

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    Back to the Berg.... when are you putting the bigger kit in one Safariberg?
    #61
  2. SafariBerg

    SafariBerg Oz Safari Addict

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    shhhh.......................let's just say there might be a testbed 610 at Condo :evil
    #62
  3. Hair

    Hair no wants or warrants

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    A 610 would be nice.

    Would you mind posting some close up photos of your Safari rear tank mount. I am looking hard at upgrading to a 570 or bigger if they come out. Our local dealer says that his 570 has a range of 50 miles. I need to extend that to 120 miles for the bike to be useful to me.

    Great writeup. Thanks
    #63
  4. SafariBerg

    SafariBerg Oz Safari Addict

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    One simple mod for the new '09 Bergs is adding the optional EFI map switch, the black rubber dodad to the left of the speedo. It has 3 settings

    3 = the stock setting

    2 = agressive / race mode

    1 = soft mode

    for our bikes we leave them set on 2, it makes them a little snappier across the rev range and a bit sharper bottom end and mid range.

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    #64
  5. Sylvia

    Sylvia vir sapit qui pauca loqui

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    #65
  6. SafariBerg

    SafariBerg Oz Safari Addict

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    The 2009 Husaberg Rallye Racing team that is competing in this years Australasian Safari rallye here in Australia is very pleased to announce that a sponsorship arrangement with RV Aqualine / Safari Tanks of Australia to produce long range fuel tanks for the new 2009/2010 range of Husaberg FE offroad motorcycles has resulted in the development of a excellent modular tank system.

    <!-- m -->http://www.rvaqualine.com.au/home.php<!-- m -->

    The new tanks will retain and utilise the existing stock 8.5L main tank and fuel pump system. The front add on tank will add an extra 7.5L to the main to give a total of 16L.

    There will also be available a rear rallye style saddle tank that will hold a further 10L, this retains the stock exhaust muffer mounting.

    So a total fuel capacity of 26L will be achievable.

    The tanks will be fitted to six of the teams FE570's for the Safari in the first week of August as real world competition testing. Upon completition of the event feedback will be provided to RV Aqualine which will be put into the production tanks for general sale.

    Any queries for the timeframe of production sale please email

    <!-- m -->http://www.rvaqualine.com.au/page.php?sId=5<!-- m -->

    With the addition of the extra 4L of the underseat sub-frame modification a total of 30L is achievable which is right on the money for Dakar and other longer rallies :thumbup

    The tanks are a nice fit and feel real comfortable when on the pegs and siting.


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    #66
  7. coak

    coak Addicted to Rally Racing!

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    Awesome, that's a relief that we've finally got the tanks. They look pretty cool. I bet there will be some drooling being done over the Husaberg rally bikes...... by riders and spectators alike....

    Great work Garry!
    #67
  8. LC8TY

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

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    Wow!!

    The 570 berg just got a whole lot more interesting. :thumb
    #68
  9. troy safari carpente

    troy safari carpente Team f5oolery

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    ie; the competition can't copy your ideas... if they're only just finished in time for the start!? :ear

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    #69
  10. SafariBerg

    SafariBerg Oz Safari Addict

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    So the end result for the Safari FE570 rallye bikes

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    The bikes worked very well for the Safari, a real test with 6 bikes and about 20,000 rallye km under the belt by the end of the event.
    • no EFI issues at all so the fuel filter mods have totally sorted that one re contaminated fuel
    • found a need to change the head gasket material from the stock laminated one to a solid copper one
    • in the process of developing a mod to the head mount engine stay to give a little flex while retaining strength, either rubber or nylon mount
    • Aqualine in conjunction with Force Acessories are finalising the tank & mount designs based on Safari feedback for the soon to be made production run of big tanks
    With these mods the new Berg is 100% rock solid as a rallye bike :thumbup

    Now its onto Phase 2 of development...............:deal


    DakarBerg :jose
    #70
  11. kiwipeet

    kiwipeet Uber Cyber Loafer

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    With a decent sized tank (and a good looking one too.) i'd be quite keen on one of these..

    It's the only thing to distract me from the 690R...
    #71
  12. SafariBerg

    SafariBerg Oz Safari Addict

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    Took DakarBerg for its first run last weekend, just to run it in before the strip down and rebuild.

    Put 1.5hrs on it all felt good, nice smooth gearbox, now its down to business :thumbup

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    #72
  13. SafariBerg

    SafariBerg Oz Safari Addict

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    Richie, Bryan and I stripped it down to the bare essentials, lubed & checked everything, then the build began in ernest.

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    Mecasystem ICO & Roadbook control unit, Progrip foam rallye grips


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    Ohlins TTX closed cartridge kit for the forks, revalved by Chad's Offroad Setups, .47 springs + Ohlins SD2 MX steering damper

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    Stock Berg WP shock revalved by Chad's Offroad Setups, 7.8 spring, HBG shock bearing neoprene protector boot

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    Force Accesories Dakar bashplate with 3L water compartment on RHS and tool box on LHS seen here, HBG clutch case saver

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    Moto Composits clutch CF cover + Akrapovic CF exhaust heat shield + HBG plastic frame protectors

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    #73
  14. LukasM

    LukasM Long timer

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    SWEET!!! :clap

    I am seeing lots of Mecasystems stuff on there. Is that rally navigation front end Husaberg specific or a KTM one adapted? Let's see the fairing.:eek1
    #74
  15. SafariBerg

    SafariBerg Oz Safari Addict

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    We are using the Mecasystem nav tower and fairing for the KTM530 Evo 2 kit, it is only lightly modified to fit the Berg, a bit of machining on the bracket that fits the steering headstock and a trim to the bottom of the fairing where it joins the tank. The rest is stock Mecasystem brackets etc.

    Looked at using the KTM 690RR nav front end as well................BUT very expensive, even more than the Mecasystem kit and also while making the decision KTM announced they would pull out and hence no service truck be there. (though now they will be !!)

    So then at the time switched to Mecasystem as they will have a truck at Dakar to buy spares, plus we have a rider on the inside of the Mecasystem team as a contact, Annie Seel, so will be able to get spares if needed without too much drama hopefully.

    Also Jaybo here ran the same gear on his 530 for the Safari and has been able to help out re advice setting it up etc.
    #75
  16. Antz69

    Antz69 n00b

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    is there a reason why the coolant pipes go around the rear of exhaust port ? looks like the hose is touching the toolbox lid now ... adaptor arrived today for camelback drink tube onto water res.

    anth @ force
    #76
  17. SafariBerg

    SafariBerg Oz Safari Addict

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    The radiator hose goes that way stock, we had to relocate it over the external oil line as it was being too constricted on top and we were worried about it restricting coolant flow.

    The hose touches the top of the tool box but is not a problem re opening it etc. The tool box is great, good volume, in fact the whole unit is great very happy with it. :clap
    #77
  18. SafariBerg

    SafariBerg Oz Safari Addict

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    [​IMG]
    TM Designs chain guide with 49T Stealth rear sprocket

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    TM Designs chain slider, much longer lasting than a stock one

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    HBG alloy disc protector

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    Talon cush drive hub with 2.5" Excel Pro rim and heavy duty stainless steel spokes, Michelin Desert 140/80x18 with Michelin M02 rallye mousse

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    Talon hub with Excel Pro rim and heavy duty stainless steel spokes, HBG front axle puller, Michelin Desert with M15 enduro mousse, will also be using Michelin M12 and Pirelli Scorpion MT410 front tyres all with the M15 mousse.

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    Barkbuster Storm handguards, good protection

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    Berg radiator fan, also have one on the LHS as well, both run of the same thermostat

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    Force Acessories radiator guards :thumbup

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    Acerbis enduro mirror, Pro Grip 786 rallye foam grips, Barkbuster Storm handguards + Mecasystem nav gear switch block

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    Berg neoprene fork seal protectors

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    The new rear rallye tank mounts made by Force Accessories for Aqualine Safari Tanks

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    Manual cam chain tensioner

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    The usual ICO odo, MD Roadbook holder with added LED backlights and the ERTF compass repeater on the RHS top, this works off the big central mounted GPS that sits on the handelbars


    Starting to look like a rallye bike !!!
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    Next big job is to fit up the nose cone fairing, headlights etc. Then its time for the sparky to wire it all up !


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    Bike graphics are being done based on an aussie green & gold flavour which the rallye jacket and jerseys are to be done in similar to this
    #78
  19. JayBo1

    JayBo1 Long timer

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    Looking great SB:clap .
    I normally wire-tie the PG grips on - one tie each end and one in the middle.
    I might have to come up and have another look in person. Certainly progressed from when I last saw it.
    Might have to chat about the CF GPS protection too.
    Can't wait to see how the fairing works out after Pete's magic wand has waved over it.
    #79
  20. mookymoo

    mookymoo Mookish Mook

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    Bike is looking sweet!
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    These rear tanks ... are they for general sale yet? Havent seen them on Aqualine's site yet - have been looking out for them.

    What sort of price are they selling for roughly?
    #80