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February 16th, 2019, 06:53 PM   #1
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I Ride: 99 ZRX1100, 06 FE450e; previously 05 EX500, 81 kz550, 07 KLX250S, 93 KDX200, 92 KLR250
Dual sporting an FE450e US

I've just become a Husaberg owner by buying an 06 FE450e. It was too interesting to pass up! It had been stored outside, so I'm dealing with faded plastics and some rusty hardware, but otherwise it was okay. 2000 miles, 98 hours. Supposedly started life with the hill climb in Billings Montana before being stuck in a corner at a dealership. A dealership employee eventually took it off their hands (built back to stock) and moved to Maine. I bought it from him.

Anyway, eventually I'd like to make this street legal to ride to trails instead of loading it up. Given that all the stock parts exist to make a street legal 06 Berg, I was thinking I could just buy the necessary sections of wiring harness, the switch module, a pressure switch for the front brake line, plug it all in, and be all set. Oh, I already have a set of blinkers. How far off am I?

Thanks for all the good info here. Cannot wait for spring and a chance to rip around on this.
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February 16th, 2019, 08:55 PM   #2
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I Ride: 2005 Fe450,2001 Fx470,1997 Fx600
I think that it is quite possible.

U.S. spec bikes were only available in street legal trim in 1998 and the 570 in 2011.

Euro and Australian FE models were mostly street legal.

It appears that you could add the missing Euro wiring harness parts #80 and #81 on the parts fiche and then the plug and play items.

Go to Munn Racing and compare the U.S. spec wiring harness to the Euro harness to figure out everything that you will need.

Taffmeisters has most of the plug and play items at good prices but not the harness itself. Taffmeisters - Husaberg, KTM, Husqvarna, Gas Gas, dirt bikes - servicing, tuning, rebuilds, parts

Rick Bozarth used to have all of the plug and play Dual Sport parts for 2009-2011 models and is very knowledgeable. SERVICES

Sicass Racing has plug and play dual sport kits for the 2009-2011 models. If you wanted a minimalistic set up Sicass has a universal turn signal kit Universal Turn Signal Kit [21-173] - $164.95 : sicassracing.com and then just wire up a rear brake light.

Procycle has a universal wiring harness at a good price.https://procycle.us/dual-sport/dual-sport-kit.html

Keep an eye on Ebay. Here is a 04 Aus harness https://www.ebay.com/itm/Light-Wiring-Harness-Loom-HUSABERG-FE450-2004-FE-450-550-650/332579339463?epid=17016218546&hash=item4d6f45fcc7: g:y0AAAOSwZrtaoNK-:rkpf:0
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February 18th, 2019, 04:05 PM   #3
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I Ride: 99 ZRX1100, 06 FE450e; previously 05 EX500, 81 kz550, 07 KLX250S, 93 KDX200, 92 KLR250
Thanks for all the info. I'm surprised they made so few street legal bikes for the US. This gives me all the options I will need! I'll update on my progress when I make some.
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February 19th, 2019, 01:26 PM   #4
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I bought an '05 650 new in 2006 and it was a leftover Euro spec model. All I had to do to it was plug in some blinkers and a horn to plate it. It already had front and rear brake light switches, mirrors, and it even had a steering lock. I was told there were a few of that era that were shipped that way.

If I were you, I'd compare the prices of the factory stuff (if it's still available) to a Tusk kit. I put one on an old 2000 Husky 610 and it was super easy and complete. An e-start model would be even easier!

Something like this:
https://www.rockymountainatvmc.com/p...lighting-kit-p
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February 20th, 2019, 05:10 PM   #5
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I Ride: 99 ZRX1100, 06 FE450e; previously 05 EX500, 81 kz550, 07 KLX250S, 93 KDX200, 92 KLR250
Yes , some of the options mentioned here are going to be cheaper than going the full factory route. Mine is definitely US spec, but has a rear brake light switch and license plate mount, which makes me think someone's started what I'm going to finish. Unless those two features came stock and just don't show up on the wiring diagram (rear switch) and parts diagram (plate mounting bracket).

Your experience was the easiest way! Albeit more expensive. That was a good find.
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February 21st, 2019, 07:30 AM   #6
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Here in Colorado we only need one brake to be street legal so by proxy, only one brake light switch. Your rear switch may be all you need (along with functioning bulb) to be legal. That said, if you plan on a lot of street riding and want people to know you’re braking a front switch would be wise as well. Good luck!
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February 22nd, 2019, 08:39 AM   #7
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I Ride: 99 ZRX1100, 06 FE450e; previously 05 EX500, 81 kz550, 07 KLX250S, 93 KDX200, 92 KLR250
Originally Posted by sanluissound View Post
Here in Colorado we only need one brake to be street legal so by proxy, only one brake light switch. Your rear switch may be all you need (along with functioning bulb) to be legal. That said, if you plan on a lot of street riding and want people to know you’re braking a front switch would be wise as well. Good luck!
I'll look in more detail at what the bare minimum is. Based on a quick review of the law, I need a "multiple beam" headlight (since it's rated over 5 horsepower!), at least one brake activating the brake light, and blinkers of course. So that narrows it down to blinkers and a "multiple beam" headlight.
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February 22nd, 2019, 11:42 AM   #8
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Does your bike already have a mask with a headlight? Some bikes have two bulbs (one low beam and the other a hi beam) while others employ a single bulb with two filaments. Lucky here to not need indicators, hand signals are ok. DOT tires? Mirror, horn? Will they check for those in your state? Husabutt is right re those wiring looms - I had a 2008 KTM 200xc that I made street legal. Under the seat, behind the mask and in the sub frame were the factory harness ends, I just had to dig up the correct harness bits to add on a taillight, etc. I presume that the base model is built on the assembly line at a certain spec level then the particular options and accessories are added from there. Good luck!
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February 22nd, 2019, 12:31 PM   #9
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I Ride: 99 ZRX1100, 06 FE450e; previously 05 EX500, 81 kz550, 07 KLX250S, 93 KDX200, 92 KLR250
Originally Posted by sanluissound View Post
Does your bike already have a mask with a headlight? Some bikes have two bulbs (one low beam and the other a hi beam) while others employ a single bulb with two filaments. Lucky here to not need indicators, hand signals are ok. DOT tires? Mirror, horn? Will they check for those in your state? Husabutt is right re those wiring looms - I had a 2008 KTM 200xc that I made street legal. Under the seat, behind the mask and in the sub frame were the factory harness ends, I just had to dig up the correct harness bits to add on a taillight, etc. I presume that the base model is built on the assembly line at a certain spec level then the particular options and accessories are added from there. Good luck!
Yes, DOT tires I have, mirror I have mounts for, and I will need a horn. Since I still have some time before spring, I might study the wiring diagram a bit and see if just adding bits and pieces will work. Also the parts list differences between the two.

Last edited by Kawestonltd; February 22nd, 2019 at 01:23 PM.
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March 30th, 2019, 02:25 PM   #10
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I Ride: 99 ZRX1100, 06 FE450e; previously 05 EX500, 81 kz550, 07 KLX250S, 93 KDX200, 92 KLR250
Looks like c337b has an 07FE550 street wiring harness for sale. I passed on the Aus harness on eBay hoping something on the same continent would pop up.

In other news, sent my rear shock out to Factory Connection for a rebuild. The Heim joint was toast, and after moving the high speed compression adjustment for the first time, it leaked fluid out all around the DCC valve. The shock will be the most expensive repair to get me going.

Also have had the exhaust cerakoted. We'll see how it lasts. Anything was better than crusty and rusty!

Spring is coming...
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