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August 19th, 2012, 07:26 AM   #1
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new bike falls off rack!

Yep, my brand new 2011 FE570S hit the pavement as I was pulling off I-5 yesterday, on the way home. I'd driven over 200 miles at an average speed of 74 mph over all sorts of horrible bumps and dips and it was fine but as I exited and slow-rolled through the stop at the top of the overpass (no one around for miles), I heard a strange sound and looked in my rear view mirrors to see my bike, still attached to the back rack but now horizontal, not vertical.

I saw blue plastic which I knew was some of my bike laying back about twenty yards. I waved to an on-coming car to please miss it...and they did (barely). It was the suspension brace I'd purchased at the dealership. If you've never used one...maybe you shouldn't...but there's more to that later. One of the mechanics at the dealership helped me put the bike on the rear Tilt-a-rack (cool racks, you don't need a ramp as they tilt) and he put the brace which sits in place between the fender and the front tire. It allows you to tie-down the bike without squishing the suspension which has got to be better for your forks.

Though there were no instructions with the brace, it seemed self-explanatory, crank down the tie-downs and head down the road. I had noticed that Huasaberg had put two horizontal tabs that contacted each fork. These tabs had slots in them, like for a strap of tie-wrap which would hold the brace in place...you think!?

I'd noticed, over the 200+ miles, that the bike had just a tiny movement back and forth on the rack, normal really since the tie-down locations aren't really pulling the bike forward into the wheel chock as much as I'd prefer, I'm going to change their location asap. Anyway, this small motion, maybe a quarter inch of forward and back motion of the front tire under the brace, eventually started kicking it out of position so when I hit the small bump at the top of the ramp, the brace fell out, the straps (4 of them) were loose and the bike fell backwards.

OK, here's the miraculous part, and it really is a miracle. The rear tire strap didn't let go and the double tie-downs on the truck side of the carrier didn't either so the bike was suspended sideways with both tires on the rack with ony the left handlebar end contacting the asphalt. The only damage was a ruined handgrip and a shorter handlebar by about 3/8" which I'm hoping Barfield, a regular contributor on this forum can weld back to length.

If my bike would've fallen off on the freeway, it would've been crushed by either a car or one of the thousands of semi-trucks I passed yesterday. A local farmer who, as he stepped out of his truck, said; "I'm an old dirt-biker from way back!", stopped and helped me sort out things and get the bike back on the rack. We cinched it down without the brace-like in the old days and it rode home with no further incidents.

I wrote this to warn those of you who use the brace and for those of you considering it. Please strap it to the forks! This may seem elementary but since there were no instructions and a veteran dirt-biker and mechanic helped me tie-down the new bike without them, I thought they were unnecessary...they are definitely necessary!

Now I'm going for my first ride, before it gets hot, gonna be over 100 today...again! Will
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August 19th, 2012, 09:59 AM   #2
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Re: new bike falls off rack!

Bummer!
You should just trim the other bar down to match. 3/8" is near nothing, don't think you'd even notice it. A masonry cut-off wheel will cut aluminum cleanly. Can square off the ground down end easily with it too.

What part of I-5 ? It's quite the long road. In other words, where did you go riding today?
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August 19th, 2012, 11:13 AM   #3
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Re: new bike falls off rack!

that's great news, i was cringing just reading your title, picturing bits of berg along a highway for a mile or two.

we all use tyre downs (translation: tire downs) on the rear wheel so that no matter what happens to the front tie downs the bike is going to stay put. http://www.kyaracing.com.au/

i think they ship them to the states now which would probably cost a fortune but if you don't have a local version then you could always make something similar.

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August 19th, 2012, 11:55 AM   #4
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Re: new bike falls off rack!

Idle, I picked the bike up at MPC in Roseville, CA and was at the exit to Avenal when the bike came unglued. I rode it today for the first time out Santa Rita Creek Road. From my house to the top of the grade, where you have and ocean view, was 16 miles.

About 3 miles back down the grade toward home, the damn thing died/lost power quickly so I pulled in the clutch and it died. Yes, it flashed the blinking code but the two-digit code never came up. After sitting for about ten minutes it started and I made it about 1/2 mile till it died again. Called my wife for a ride home as I was now 12 miles from home.

Closest KTM dealer is two hours away in Santa Barbara. Closest Husaberg dealer/mechanic is in Santa Cruz, about 2 1/2 hours away...not real sure about this bike!

hoosie5seventy thanks for the link to tyre downs, fantastic idea! I'm an inventor as well and have been brainstorming all night and morning about a better system, they nailed it pretty good and I may pick up a set.

I'm still thinking that just for my own peace of mind, I would like something that absolutely kept the bike from ever tipping backward off the hitch carriers that so many of us use. I'm thinking of an upright of 2" square tubing that would plug into the carrier like the carrier does into the hitch, with a pin to lock it in position. It has an upright of 2" square tubing about 36" high and a square of 1/4" steel welded to the upright. The square would have a piece of upholstered foam and the bike would be strapped to it which would hold it from moving frontward, rearward or side to side. There would also be no pressure on the suspension as the holding would be from the frame strapped to the upright or the square section. Still thinking about it.
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August 19th, 2012, 01:44 PM   #5
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Re: new bike falls off rack!

Originally Posted by willhesch
IdleAbout 3 miles back down the grade toward home, the damn thing died/lost power quickly so I pulled in the clutch and it died. Yes, it flashed the blinking code but the two-digit code never came up. After sitting for about ten minutes it started and I made it about 1/2 mile till it died again. Called my wife for a ride home as I was now 12 miles from home.
if i remember correctly, pre oct 2011 they were using unreliable fuel pumps, there's a thread somewhere about how to identify if you've got the old dodgy one or the new reliable ones.

they were still having issues with the fuel filters being too fine on the 2011 models, at least here in australia. mine was a 2012 and the dealer had installed the correct filter sent out with the 2012 models. might be something to do with that? i'd suggest looking at the threads to do with pumps and filters and see if your problem sounds similar. hope it's an easy fix, bummer of a thing to happen on your first ride!

re: the tyre downs,the nice thing is that if you position it correctly it's pulling the bike forward too. so even if both tie downs at the front the bike is held very securely... you probably wouldn't even notice any difference unless you saw broken tie downs flapping in the breeze through your rear view mirror.
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August 19th, 2012, 06:24 PM   #6
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Re: new bike falls off rack!

It's flashing three slow and three fast which, according to the owner's manual, indicates a injector fault.

WTF?!! A brand new bike and it dies in the middle of nowhere because the injector is plugged? I put a fuel sock in yesterday at the dealer's so the tiny filter wouldn't be affected with debris but it looks like it happened anyway.

Not sure what to think. Seems like a nightmare coming true...
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