Husaberg '09 FE570 rallye bike build

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

  1. SafariBerg

    SafariBerg Oz Safari Addict

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    not just yet, but must be very soon, best to email them and ask,

    cost will be similar I imagine to the other ones like the CRF-X ones
    #81
  2. SafariBerg

    SafariBerg Oz Safari Addict

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    Just got the final designs back from the graphics guys, Tubby Signs in Cooranbong NSW

    Should be pretty obvious where we hail from :D

    [​IMG]
    #82
  3. Bigem

    Bigem Long timer

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    Hey SB, are you keeping a running tally on what its all costing to put together?

    I'm thinking "lots" might just about cover it!!

    Looking awesome mate!!
    #83
  4. SafariBerg

    SafariBerg Oz Safari Addict

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    The bike is the bargin cheap bit, plus you get to still have it later to sell if need be.

    The killer is the entry fees etc :cry

    Even the bike has its own entry fee :eek1

    Best just not to think about it
    #84
  5. hicksamunga

    hicksamunga Adventurer

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    the build has turned out looking absolutely awesome well done
    #85
  6. SafariBerg

    SafariBerg Oz Safari Addict

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    Nearing completion, and just as well as it needs to be in the crate and at the shipping agents very soon to head off to Argentina to get there mid Dec.

    [​IMG]
    Double Narva HID 35w lights, these are great, fire up instantly unlike many other HID's, compact, light and fit the Mecasystem brackets perfectly. BUT expensive like all HID's. Also the ballasts are really compact and dont take up much room.

    However given the high chance of being still out on the course after dark the need for the best lights possible is high. On a lot of days it is only the top 50-70 riders that get back into the bivouac during daylight, all the rest come in after dark. Backing up the HID's on the bike will be a Trailtech HID SCMR16 helmet light as well if needed out on a Selective stage after dark.

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    The fuse board, and Narva HID ballast just to the right, with the blue High & Low beam switchs above, the switchs glow when on.

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    Still got as bit of work to do to tidy up all the wiring.

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    Relays and fuses at the back of the HID's

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    Back up ICO thumb switch and euro start button, ditched the ADR one.

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    Going with the stock muffler and Barret end cap for durability, considered the Akrapovic but the stock muffler is a lot stronger, especially the mounting points.

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    Added a Mecasystem bigfoot to the side stand to help a bit

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    A bit blurry, but you can see the CanAm quad bike external fuel filter we have added just behind the cam chain tensioner. The filtration system is a 3 stage one, 1) there is a Profill filter screen on the intake to the fuel pump, 2) the stock Berg/KTM in-line filter inside the tank and 3) this CanAM one external and before the injector. After experiencing fuel contamination issues at both Condo 750 and Yilgarn Rallye early this year, this system was developed for the Safari and works a treat, no more fuel issues :wings

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    Rear subframe fueltank breather hose system, this gives an extra 4L fuel.

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    The fuel line is first wrapped in heat sheild, then spiral wrapped for protection.

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    Rear subframe breather joins up to the front tank breather


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    Great alloy plate mount for both tool bag and big 80x80mm LED dust light, bolts up to both the rear tank and the mudguard. Tool bag will carry light but bulky stuff like rear 18" tube, spare fuel pump, injector etc.


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    Pretty much just need to finish off the wiring and bolt up the fairing now



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    A plug for the dealers who are helping us out :D
    #86
  7. MexMex

    MexMex Been here awhile

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    Amazing work. I looking into this thread with hopes that in couple of years I will do the same myself.

    Some questions, hope you have the time to answer:

    1. What are those fork cups? Why did you changed the OEM ones?

    2. Why you didn't use a fuse board / block which is more compact and easier to wire in comparison to separated fuses ?

    3. Are you going to run everything on the OEM stator or did you modify it in any way? What about the battery? the 7 Amp OEM?


    Wish you all the luck in the world man! :clap

    M.
    #87
  8. ChrisCrossed

    ChrisCrossed Now sans KLX...

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    Brilliant stuff Mr Berg. Remember to place an exclusion zone around Hondas!
    #88
  9. SafariBerg

    SafariBerg Oz Safari Addict

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    see some edits below as well
    #89
  10. troy safari carpente

    troy safari carpente Team f5oolery

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    VERY nice Mr Berg... very nice... :clap
    #90
  11. SafariBerg

    SafariBerg Oz Safari Addict

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    [​IMG]
    Have taken the stock Berg seat and replaced the foam with a soft Gel GUTS Racing foam unit from the USA, then replaced the top part of the seat cover with suede and added a time card pouch. Though after 8,500km on the thing I'm sure there will be callouses on the callouses :(:


    [​IMG]
    The bike is almost done now, it is the real tricky bit of finalising the front end bits and tidying up all the wiring, than last of fit the fairing.

    There is so much more to fit to a Dakar bike than your average Condo or Safari bike :deal
    • big central GPS & Iritrack unit that sits on the bars.
    • GPS repeater up by the top ICO that shows you your compass heading
    • Sentinal which lets you tell ASO if you are down
    • Sentinal horn that buzzes at you as a car or truck is about to pass - assuming they press their button :(:
    • Crash warning flasher, if you come within 500m of somone who has crashed and pressed the buttons on their Sentinal it flashes to let you know there is a crash site ahead, useful to try to avoid crashing also :wink: and also to see if you need to render assistance
    • 3 antenna for the GPS, Irridium phone hook up and Irritrack unit
    • Sarsat unit which is a EPIRB type device
    • Speedox unit that is hooked up to the GPS and the Sentinal horn which beeps at you if you are over the speed limit in a speed limit zone - not critical but useful to avoid big time penalties and big fines in Euro
    • plus the good old MD roadbook holder & 2 ICO units
    Added to this lot are
    • 2 HID head lights & ballast units
    • 2 KTM LC4 plastic tool boxes to carry safety gear like flares etc
    • first aid kit
    • plus all the wiring fuses, relays etc etc etc
    a good 10kg all up :(:

    And given the Berg is a very compact bike there is not much real estate to hang all this stuff off


    Still almost done :wings

    Had a local 690RR rider drop by yesterday to have a look............."hmmm its small & light isnt it"

    :evil
    #91
  12. poppy

    poppy Slow and Steady

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    G'day Safariberg, is the idea behind all the perforations in the sticker kit to help with the breathing of the plastic that the safari tanks are manufactured from and allow them to stay there ?. The bike looks great.
    #92
  13. SafariBerg

    SafariBerg Oz Safari Addict

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    yeah, otherwise will peel real quick
    #93
  14. K2vodka

    K2vodka Been here awhile

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    Best of luck. Good to see a 'Berg being run in Dakar.

    I just picked up my '08 FE 650 the other Friday in Idaho and took the long way back to Chicago, 2600+ miles vs ~1600 miles.

    It's love. This baby seems to be able to do most everything.

    I've ridden her everyday since picking her up, rain or shine.

    She is meant to be used for ripping up the city during the winter.

    Thanks for sharing all the details. I'll be watching and rooting for you.

    Cheers!
    #94
  15. Wilmo

    Wilmo Orange Fever

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    Are you going to test run the new bike locally Gary before shipping it? Let Guy and I know...we'd be keen to check it out in the flesh! Are you airfreighting it to South America?
    #95
  16. SafariBerg

    SafariBerg Oz Safari Addict

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    it goes into the crate tomorrow morning and then off the to shipping agents to go by sea, takes 4 weeks to get there by mid Dec

    air freight cost X 6 as much :(:

    so no testing, just the first road section of 120km after the ceremonial start in BA to the first bivouac
    #96
  17. DRjoe

    DRjoe Long timer

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    No testing:eek1 you are one brave man.

    Good luck
    #97
  18. SafariBerg

    SafariBerg Oz Safari Addict

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    true not the ideal, but will have 5 days in BA before the start to check things over and the first day road section on Fri, the first special is not till Sat, thus an overnite bivouac service opportunity if anything shows up.

    plus we did do almost 20,000km testing with 5 x 570's in the Safari, not exactly the same of course but we have a pretty good idea what to expect

    its either that or pay an extra $5k and send it by air.................:(:
    #98
  19. Bigem

    Bigem Long timer

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    Its a work of art mate.

    Its a shame you cant shake it down before it goes.

    There seems to be a lot of weight over the front-end though, how do they go in the soft shit?

    I imagine it would be a bit like plow if you don't get up it!!

    Beautiful bike.
    #99
  20. DRjoe

    DRjoe Long timer

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    Can you give it a shake down run over there before the start or are there some rules against that.

    Thanks for sharing your experiences with us it's probably keeping the dream alive for lots of people.