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Discussion Starter · #1 · (Edited)
Well, I think some might find this somewhat interesting to read, and it's good to collect all the info and pics in one thread so here goes nothing.

Back in -11 I wanted something different as I was thinking that bikes (sportbikes) are too boring, and I was desperate to choose whether to try a fast car or get different style bike. I test rode few times friends -10 yz450f in motard trim, and I immediately knew what I wanted. This is how riding a bike should feel, completely FUN!

Trying to sell my gsxr without much luck (got trade offers anything from lawn mowers to Skyline GT-R's) I decided to call to a dealership who sells KTM's and Husaberg and see would my bike be any interest to them. Got quickly a reply that trade would be no problem and a new -11 FS570 Husaberg would be a nice bike for me. After a nice test riding on street and local race track I was hooked. My gsxr felt even more boring after trying a 50hp dirt bike lol!

Month later, I finally got my first new bike and first Husaberg. Like everyone knows, it looked something like this.






Took not long before I started tinkering and modding the bike, as I think knowing and wrenching your toys is as important as riding them.

First summer was mostly cosmetical upgrades and getting used to a completely different style bike. Then it started to get a bit serious when I really wanted a bit more out of the bike.

Got new Excel wheels 16.5" / 3.5" and 17" / 5" with new revalved suspension, Beringer brake system, FMF full titanium exhaust, dna panel air filter with seat mod to suck in more air at high rpm's. This setup was good for the next season and really waked the bike up!





Put in on a dyno untuned to see what it made with the simple bolt-on mods it had (had the user setting tool at that time also).



Not bad, but still not what I was after. This bike lacks top end badly!!





So it was almost the end of season -12 and it was time to take the bike apart again and think what to do with it.
Was thinking of selling it and finally getting a fast turbo car to have fun with, but something tells me to keep it and build it. So why not?

Started to search and order parts what I think would work well. Wanted to keep stock bore and stroke, as I want somewhat same revability like smaller bikes and easy handling.



While I had the motor out from frame I wanted to make things more easy and professional by building a jig to mount the motor in fixed position. Low cost end result:




With new 46mm throttle body.




Oem 42mm....hahaha








Some more parts...


13.5:1 CP piston






Coated with techline CBX ceramic heat barrier coat on top and dry film lubricant on skirts.




Custom grind camshaft.




New FP-Engineering / Ignijet ECU.






While collecting more parts I wanted a new fresh look. Wheels were in a really bad shape with dings and scratches everywhere, and also forks looked too plain with clear anodizing. Torn the wheels apart, stripped old ano from rims and sanded them down to 2500 wet and polished for mirror finish. Sanded and polished wheels nipples also, and sent everything to anodizing.





End result.






Then it was time to get the head ported and matched for new 46mm throttle body, as all the power on n/a motors are made in the head, and it needs to be done well to make good power!


After a month or so I got the head back. Looking good!





Intake







Exhaust







Combustion










Have had some motivation problems so progress has been slow, but looking at all the trick stuff made me want to keep working more harder to get the bike back in one piece.

Some cosmetic stuff more and forks rebuilt with SKF seals and polished the inner tubes on lathe for super smooth no-stiction finish.







No more crappy KTM bolts that rusts. :D







Wheels turned out great (tubeless using 3M 4412N sealing tape)!!









Couldn't refuse when the opportunity opened up.

Brand new Suter slipper clutch, just needs stronger main spring (sprung for 450's)






Welded up a titanium bung on the FMF exhaust for wideband AFR meter for precise air/fuel ratio logging on dyno.





Errr....sure? :D






Got the final (lol yeah right) batch of parts yesterday, and most importantly valve shims to get clearances in spec for both stock and new custom cam!









Hopefully the workbench will be empty in a week or so, and lots of braaappp can be heard. Still got stuff to do.
Piston to valve clearance checking with new cam, throttle cable needs different end to fit to new throttle body etc.


 

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Looking nice!
 

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Hey no porn allowed........:D well bike porn of coarse... great job, good lookin parts....love the motor stand...:thumbup: I love watching others spend disgustingly large amounts on their SM's.. makes me feel better about myself...
 

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My God, every new build I see make sme so jealous! Need to win the lottery or something!! :rant:

Maximum respect man, your pics have given me a pair of tented jeans.........:bowdown::anim_peep:
 

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Husaberg love! awesome!
 

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Discussion Starter · #16 ·
Is that a Domino housing in the top right? You converting to a single cable? I just did the conversion on my WR250X with a custom Motion Pro cable and Domino housing. Results are great.
It's OEM 09-12 Berg 2-stroke throttle housing (domino) and Motion Pro T3 throttle cable. The new throttle body only has single cable pull system, so stock 4-stroke cable with return side is useless and it's way too short to use anyway.
 

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Discussion Starter · #18 · (Edited)
I managed to solder a new cable end on the Motion Pro T3 throttle cable that is mean't for 2t ktm's and Bergs.
Made from M6 bolt and just drilled hole in the middle and cut to size.

Does not look pretty and I had to make it 3 times because first time I screwed it up and forgot to screw the lock nut on the adjusting screw before soldering. Second time it would not hold up at all. Could not get the solder to flow in even though I used solder pot that I made and heated with butane torch. Third time I had to cut the cable liner shorter, because there was not enough cable left from my previous mess-ups.

Cleaned everything with acetone and dipped cable wire in acid salt, and wished for best. Should have used flux, but all I had was 100% silver which would not melt or eutetic 37/63 silver/lead/tin solder that I used.

Seems to hold up now even though it looks somewhat unsoldered partially. Put it on vice and tried to pull and yank the cable with all force I had.


Starting to assemble the motor today and see what happens.





 
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