Husaberg '09 FE570 rallye bike build

[JayBo1]

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.

[InertiaDRZ400]

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!

[hicksamunga]

how's the build going?

[SafariBerg]

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.



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



Overall they have performed very well but with a couple of niggles with the injectors not liking contaminated fuel




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


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 . 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 , 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

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 and it will be the fastest bike in the field bar none

on to the build

The nice shiney new 570's quickly go from


to


to


and then before they even turn a wheel in anger to




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.



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.




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



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.





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





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


Though a couple of bikes are running the Akrapovic slip on


Header heat sheild




Berg hardparts case saver guard and 15T sprocket up front


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



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







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.



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





Berg hardparts neoprene fork seal savers to keep it all happy




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




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



Berg hardparts plastic frame protectors

[LC8TY]

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?

[SafariBerg]

Originally Posted by LC8TY

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?

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



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 , he is physically a big strong guy and likes the V8 grunt

[atgreg]

very, very nice !!!

[hicksamunga]

Originally Posted by atgreg

very, very nice !!!

+1

[ChrisCrossed]

Originally Posted by SafariBerg

Brandon being the macho boy he is has opted for the 650 for the Safari , he is physically a big strong guy and likes the V8 grunt

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

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

[Sylvia]

Berg porn



love your work Gary...

[stteve]

Originally Posted by SafariBerg

.....

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 .....

Wow, very nice build rally bike, but can you still do the 2010 Dakar in this one, since it is 450cc max (or 660 with a restrictor)?? It is a shame not to see a bikle like this cruising the giant dunes in Chile.

[SafariBerg]

Originally Posted by stteve

Wow, very nice build rally bike, but can you still do the 2010 Dakar in this one, since it is 450cc max (or 660 with a restrictor)?? It is a shame not to see a bike like this cruising the giant dunes in Chile.

yup all good, been confirmed by ASO

[savage]

Originally Posted by SafariBerg

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



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 , he is physically a big strong guy and likes the V8 grunt

Gday, Your FE looks choice.
Can you give me a quick review on the new Ohlins damper, Ive just bought one for my 450FE and I'd like to know how they compare to the older Scotts.
Also do you intend to service the Ohlins yourself, how do you change the oil? I've been told it has to go back to a dealer, and at the recommended 20 hour service interval, as far as I'm concerned thats not on!
Thanks for any feedback..Sav

[SafariBerg]

Originally Posted by savage

at the recommended 20 hour service interval, as far as

this is not real, I intend to get it service by a authorised Ohlins dealer once a year

[Baillsy]

Love your work Mr Berg, preparation is the key to any good result and you and the team look as though you have knuckled down and are putting in the hard yards to get these bikes humming. Good luck with the rallies and hope you can give the jap bikes a touch up.
The husabergs are lookin good and even better in rally trim. Good luck guys