Husaberg '09 FE570 rallye bike build

[pete40]

Back to the Berg.... when are you putting the bigger kit in one Safariberg?

[SafariBerg]

Originally Posted by pete40

Back to the Berg.... when are you putting the bigger kit in one Safariberg?

shhhh.......................let's just say there might be a testbed 610 at Condo

[Hair]

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

[SafariBerg]

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.

[Sylvia]

Handy little mod Gary.

Found this on the 2010's. The motard looks good.

And the patent on the tubeless spoke wheels.

[SafariBerg]

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.

http://www.rvaqualine.com.au/home.php

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

http://www.rvaqualine.com.au/page.php?sId=5

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

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

[coak]

Originally Posted by SafariBerg

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.

http://www.rvaqualine.com.au/home.php

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

http://www.rvaqualine.com.au/page.php?sId=5

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

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

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!

[LC8TY]

Wow!!

The 570 berg just got a whole lot more interesting.

[troy safari carpente]

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

Originally Posted by coak

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!

[SafariBerg]

So the end result for the Safari FE570 rallye bikes





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

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


DakarBerg

[kiwipeet]

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...

[SafariBerg]

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

[SafariBerg]

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


















Mecasystem ICO & Roadbook control unit, Progrip foam rallye grips



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


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


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


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

[LukasM]

SWEET!!!

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.

[SafariBerg]

Originally Posted by LukasM

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.

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.