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My Husaberg Project / Picture thread

154061 Views 217 Replies 69 Participants Last post by  parriman
So I decided to write up a bit of a "project" thread! Ive never done one before and Ive been a member of these forums for quite a few years now, so I fealt like sharing. Its probably more just a "picture progression" thread than anything else... but everyone loves pics so.. whatever!

I learnt to ride a dirt bike when I was about 18 or so. Rode lots of trails, got my license, a registered trail bike and started riding to work. I've been a fan of supermoto for quite some time now, after seeing a friend race in a local series many years ago. I guess the love for dirt bikes and the joy of riding on the road to work is what lead me to it. I got my hands on a ktm 525 exc, threw some 17's on and some decent big brakes and fell in love :) Did a couple of trackdays too at the local kart track but was never super serious about it.

While I totally loved the sumo, I also wanted "more." I ended up getting myself into debt by purchasing a '07 Superduke. Had the best of both worlds really.

I would alternate riding each to work throughout the week. I (reluctantly) ended up selling the 525 so I could travel overseas for a couple of months and help me out with a bit of cash. The thing was burning a bit of a hole in my pocket anyway (after the rebuild :( )
I had some bad luck in traffic a couple years back; got t-boned by a car that failed to give way at some traffic lights.

I wrote both the superduke and car off, but wasn't too badly injured, so before I was out of my cast and off my crutches I was in the hunt for a new bike. The natural progression was a 2009 Superduke R.

The bike was a total animal.. Probably a bit too much for me really. It was amazing when riding it super aggressive, but for riding to work every day... it sucked. It was just not a commuter friendly bike. So I started planning another supermoto build. If you haven't worked it out by now, I was a bit of a KTM fanboi. So, a new ktm 530 exc was going to be my starting point. I sourced and priced up all the parts I wanted and started saving. Then I saw a news item on the web somewhere, showing Husaberg's new FS570 and my plans pretty much went out the door.

Headed to my local dealer and made some inquiries. Got a price, slept on it; placed an order for one the next day. The way I saw it, I could buy a 13+ grand ktm exc and spend a fair bit of money setting it up OR buy a bike thats got pretty much everything I want right outta the box for just under $16,000. The bike arrived a few weeks later (around August/September 2009 I think) and was one of the first in the country. Rode it down the street with a massive grin on my face, hit the brakes to stop at the first set of traffic lights and nearly pooped my pants.. The front brake wasnt working... Was only going quite slow so the rear got me to a stop. Did a U-turn and went straight back to the dealer. The front rotor was completely warped. It would only make contact with the pads on a tiny section, the rest of the time = no brakes. We grabbed the disc from the crated FS570 and off I went, this time, grinning while accellerating AND braking.

I didnt really do much to the bike for the first few months. The motor was extremely tight when new. The more km's I put on it the better it became. I bought myself a slip-on akra pipe and a DNA filter, which livened up the bike a fair bit through the midrange and a little increase in torque.

Other than that, I really didn't change anything on the bike until a few months ago. Maintenance has been fairly good. I don't stick to the manual recommendations; usually ride the bike over the recommended oil changes but not too far. The valves were adjusted after the break in period and haven't moved since. I never experienced any fuel pump issues or dodgey fuel mapping problems that I read about on forums. Its been a flawless & fun commuter for close to 2 years!

Then a friend of mine who raced 600's convinced me to do a trackday with him. I couldn't decide on which bike to ride, so I took the SDR and the berg. Track was Lakeside International Raceway, a track which used to host a fair amount of racing but was shut down around 10 years ago as housing estates were built up around the track and noise became a real issue for residence. It reopened a couple of years ago, pretty much just for trackdays and a fairly strict noise limit. The akra pipe even with the insert was waaaay too loud, so stock pipe had to come out of retirement.

I absolutely loved the trackday. Entering into the slow group on the berg, I took it easy for maybe..2 laps? The rest of the morning was spent destroying the right hand side of my tyre, passing sportsbike after sportsbike around the outside of pretty much every turn. I had a glimpse of the speedo going into Turn 1, 183km/hr. Was pretty impressed with that! The chuckle inside my helmet as I passed each sportsbike was partnered with "you just got passed by a dirtbike" running through my head. I did ride the SDR for a few laps, but pulled in with an electrical problem; a wire earthing itself onto the frame somewhere. The berg backup bike was fired back into action though :)

I was solidly hooked after that day. There weren't enough trackdays to feed my addiction, so like alot of you, I decided to go racing :) I think it was like $100 to get a front MX plate and a new rear fender that didn't have any lights on it. Changed it all over in 20 minutes or so.

One of the things that always annoyed me about the bike was the front brake. The brakes I had on the 525 felt incredible, as did the brakes on both of my superdukes. These magura brakes never really impressed me a great deal. I saved up for a brembo caliper and 16x18 MC.

It was night and day difference. Felt so so sooo much better. Threw some numbers on the bike, headed for the track.

(I forgot to take the sidestand AND the horn off.. whoops!)

The race series was a one weekend only event at Morgan Park Raceway. Road racing only, over 2 days. Qld road racing championship. The class I entered in was called Formula 3; open for 4cyl 250s, V4 400s, V2 650s, and any size supermoto. I was 1 of 2 supermotos in a field of sportsbikes. Day 1 saw the area have an incredibly large amount of rainfall that carried on throughout day. I rushed to purchase some wet race tyres and get them fitted in time for qualifying, with F3 being the first session of the day.

I was blown away by the amount of grip these tyres offered on a track covered in 15mm of water. Somehow I qualified 2nd on the grid. Got a great start to race 1, managed to overtake the VFR400 that was on pole around the outside of turn 3 and went on to win my first ever race. With the geometry of the dirtbike, I felt fairly comfortable sliding the bike around in the wet where as the sportys struggled a bit. Race 2 I managed to get the holeshot and gave it all I had, however I wasn't the ballsiest rider on track and finished 2nd.

Day 2 was the total opposite; dry track & clear blue skies. Perfect really. I got onto track late for qualifying, and only got 2 decent laps on the dry track with my fast lap borked by a crasher infront of me.. Qualified at the back of the grid. I pretty much got hammered by everyone in the dry and finished at the back of the pack all day, but managed to knock about a second off almost every single lap all day long which felt pretty good! I had decent corner speed and was decent on the brakes, but the sportsbikes would always be quicker than me down the straights (the 183 km/hr at lakeside was due to the last turn being a fast flowing turn downhill, Morgan Pack had none of these. Topspeed here was about 158 km/hr.) I just had to wave bye to them as they went passed. I found that with the stock gearing (14/38) the bike doesnt really hit the rev limiter anywhere in the top few gears, so I put on a 44 tooth on the rear before the next track day and found a huge difference, for the better.

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Ive become totally addicted to the sport. Ive made a heap of new friends as a result, and I almost enjoy the socialising part of it as much as the racing. I've got much to learn, but I keep focusing on improving every time Im on track. Like alot of you, Ive really enjoyed personalising my bike and spending money on it. So, I threw on some new graphics :)

The next event, also at Morgan Park was a proper supermoto race. Short track bitumen, small dirt/grass section. While I was pretty slow everywhere, I got totally addicted to the sound of that rear wheel squeeling going into the tight turns after mashing down 2 or 3 gears. Had a couple of small crashes in the dirt but nothing major. Knocked about 11 seconds off all my times throughout the weekend, was definately happy with that :)

Up against alot of 450's, the 570 doesn't really seem to have much punch in the top end. Heaps and heaps of torque, but the power seems to fade off a bit. I started looking into engine improvements and I guess I am getting pretty carried away with it all. I'm not the fastest rider out there, so its in the back of my mind that any engine mods probably aren't totally necessary... but fuck it. I enjoy playing with it :)
First purchase was a bored out 44 mm Throttle Body from Bergos. Its not much to look at, but was told it provides some decent gains.

Before I started tinkering with the internals however, I found out what was on offer first. In bone stock trim, with roughly 140 hours on the motor, the bike put out 56.20 rw hp, and 40.11 ft-lbs torque. It was more than I had expected to be honest. I threw the akra slipon and the DNA filter back in for another couple of runs. The best result we got was 56.20 rw hp and 41.32 ft-lbs torque. We actually lost a fraction of topend but gained a huge amount of torque in the bottom and mid range, and a slight increase up top. My initial impressions of the mods was fairly spot on; it did liven the bike up.

The final lot of runs was done without a seat. If you arent familiar with the husabergs layout, the airbox and filter is under the seat, just behind the fuel cap. With the seat off, we had a fairly massive gain all round. The smoothest of the runs saw 58.22 rw hp, 42.18 ft-lbs torque, however I did see one of the runs hit 59.8 hp.

The bike came off the dyno, headed straight for the shop with the seat going to the upholsterer. A nice big hole was cut at the front of the seat, with some mesh sown in to stop my balls being sucked into the motor.

I got a few little tidbids added alongside the bigger throttle body.. Some new anodised bolts alongside some blue rad hoses. I heard bling shaves 0.01 seconds off my laptimes...!

I was dying to try the new mods out, so I spent the 20 minutes it takes to put all of the road going gear back on the bike to use and went for a blast around the block and up a couple of little windy roads. Holy fuuuuuuck. The bigger TB combined with the seat hole has made a massive difference. I think I may have lost a little bit of bottom end power/torque but the increase in mid range and top end feels like a whole lot. The ride was at night time and I had some trouble seeing where I was going as the front wheel was skyward bound the whole time with the headlight illuminating the trees above me. The downside of it all, the near perfect (a tiny bit rich) fueling now feels really lean. I need to get the bike back onto the dyno...
I am fortunately quite chummy with my local KTM dealership, supplying them with a constant stream of work with my 3 bikes (Ive also got a KTM 350sx..) and have convinced them that it would be in their best interest to purchase a ktm/husaberg User setting tool that will allow ECU adjustments to all the new Ktm / berg fuel injected bikes (...and let me borrow it..) They also have one of the most experienced ktm mechanics in the country on board who does a great job in the workshop. So... I am currently waiting for the tool to arrive before proceeding any further on the dyno.
In the meantime, this arrived :)

With the FS570 only having a 4.25 inch rear rim, slick fitment isn't the best, so a 5" alpina will work nicely :D
That is all Ive got for now.. I would like to update this thread as I progress with the work to the bike, as am I due for a new piston quite soon. I would like to swap it out with a high comp piston and give the head a port & polish.

More to come.. :)
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Thanks for the kind words chaps. Im glad you enjoyed reading it; I had fun writing it. As soon as my KTM dealer get their UST in, I will be back to the dyno! Ktm Australia announced recently that all KTM / BERG hardparts are now 50% as their parts sales have dropped seeing how its sooo so so cheap to buy parts from the USA. As a result, there is a bit of a backlog on part orders and the UST is taking its time to show up..

Torque Monster, I am guessing you would probably be able to point me in the right direction for a high comp piston? I think I remember Hugo telling me that you didnt get yours from bergos? Thumper racing perhaps?
Any info would be appreciated :D
Thumper Racing - yes, just do the 610 kit and ask for whatever comp. ratio you desire - Travis can get you anything you want. Tell him Torque Monster sent you and I'm sure he will get you hooked up.

Cool, Ill try get in contact with em! Thanks.

Bloody good read that, bike looks great!

Are you going to whack a full system on it? Might as well ay :D
cheers mate, thanks for all your help along the way too :)

I think I might get a FMF ti header / midpipe, as its my understanding it should fit the stock pipe.. I need to have like a 92 - 93 db limit for one of the tracks. The doma system is just a bit pricey.
Dont you have a DB killer on your akra im sure it will lower the sound to that limit? Nice thread!:clap:
I do! It was measured at 98 db :(
Without it its like 106 db.

Its really no effort swapping the pipe over anyway. 5 mins tops.
Small update...

This arrived this morning :D

it came with a packet of 50 FMF stickers... not sure why they think I needed 50..? But ok!
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Awsome bike, the painted rims looks sweet:)

Where did you buy the blue anodized bolts?
A company called Pro Bolt
very cool man. I reposed it if that's ok. Looking forward to seeing it with the rims on!
Yeah man thats cool! :thumbup:

I check out your blog from time to time. The kiska archive sketches are awesome. No doubt I loved this one..

Do you work at kiska? Im very jealous :p
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ow! Cant wait!

I can assure you Im very eager to get those rims on too! Just havent gotten around to getting the tyres yet. I still ride the bike on the street from time to time at the moment, having the rims+slicks on is just a little inconvenient.

But... Holidays coming up soon. Should have something to show soonish :)
The luckiest part about the crash, was the fact that I flew through the air (after bouncing off the car) between two power poles and landed on the wheelchair access ramp of the sidewalk then rolled into a picket fence...of a medical centre. :rofl::bs:

I still commute on the berg from time to time, but in the last few months Ive been using the Superduke R. Ive softened the suspension up a crazy amount. It sucks if I want to push hard, but its made the bike ride-able. I also put a throttle cam on to soften the response a bit, and the bikes been tuned on the dyno (although I think I will take it to the guy that dyno'd the berg, cos he really knows his stuff.)

And I loved the 525! That thing was a total animal :) But after the rebuild, I was low on cash and I wanted to go travelling for a couple months with my girlfriend so the bike had to go. I still see it from time to time with the front wheel rarely touching the ground.
Theyre from Pro Bolt

They have websites for UK, USA and Australia.

The bolts are all pre-drilled to make it easy for lock wiring.
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Got the pipe fitted! It does actually sound SLIGHTLY quieter thanks to the megabomb... still obnoxiously loud though :rofl:

The O2 sensor is gone! And we didnt get a FI light error. Very pleased about that.

Only rode it back from the shop, so it hasnt had much of a chance to change all bluey / purpley as the Ti pipes do.

I noticed that the fueling feels a fair bit better now with the new pipe, as previously with the new TB and holey seat, it was mega lean. It still feels a tiny bit lean, but it is definately an improvement.

Before I had the pipe fitted, I had it on the dyno for a run. Currently at 58.01 rwhp. My UST arrives next week, and the bikes booked in for a dyno tune at the start of next year. Cant wait to see what we can do with the tuning software! :bannana:
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I like the look of the akra! But the akra doesnt have a midpipe, the FMF does.
Sorry guys! Dont have any pics of the bike with Alpinas on yet. I've been riding around on the street with it a little bit, and I'll be putting slicks on the new rims, so I just havent bothered fitting em yet!

I do however, have my ktm User Setting Tool now, and will be getting it tuned at the end of the week, which I am really excited about.

I was just fooling around with my camera this afternoon as the sun was going down and took a few closeups of the bike. Theyre all around the 1920x1280 resolution.
Hope you like 'em! :thumbup:

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why would I mind? :D

I just bought the midpipe and header from the FMF website. I already had the akrapovic slipon. They fit together perfectly, no problems.
hehe yep!
Its a pretty good deal for the amount of titanium you get. It fits directly onto the stock exhaust, so any slip on will work with it.

The new FMF header has made an increase in power across the rev range, just from the seat-of-pants dyno. It feels stronger right through.

With the limited amount of aftermarket parts for this bike, I would be surprised if your build was alot different to mine. The only thing I think I wont be adding is the bigbore kit.

From what Ive been told from people in the know, these motors REALLY benefit from a ported head. Theres also alot of clearance in the top of the motor. Doing small things like removing a gasket can bring that clearance down and increase power. I really need to sort out a high comp piston and get the head work done!

Make sure you get a user setting tool if you muck around with the motor. The ecu can handle pipe+filter, but it starts to lean right out once it gets a bit more serious.
My bike is at the dynoshop right now, I should have it back in a couple days. I am really looking forward to seeing the results of a good tune!!
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