KTM parts that swap to pre 2000 husabergs

Husaberg

Help Support Husaberg:

This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.
Joined
Feb 4, 2016
Messages
20
Location
Hartville, Ohio
Have had my berg now for a few months 1999 FE501E. I am educating myself on all that is "BERG" wished I would have bought it back in 99. Maybe then I could get more info.
I know many new KTM and Berg parts are interchangeable I have also learned many of my new parts I am ordering have KTM packaging.

My question is... Are there KTM parts that interchange with older bergs either directly or with minor mods.

Can we get a section for this if in fact it is commonly done. I always see this with newer bikes but not with the early ones.
I guess this will happen when the new ones become the old ones now that the "Berg" line has supposedly ended. The cool factor has now been raised as bergs become more rare.

Just wanted to start a thread where this old knowledge can thrive.
There is an oldies section at KTMTalk that is invaluable to guys resurrecting old bikes.
At least a good thread on it here might be of some consequence!
Any wisdom is appreciated!
 
Here's my 501 with the newer FC470 2001 swingarm bolted up. I will verify wheel still fits after I put in the new bearings and seals the rear brake caliper slips right on. I can get the chain guide,sliders and brake cable clips all new pieces for this swingarm I can't get all of these for the original one.
clp95inckno0ijazg.jpg



The newer chain guide "left" is much better in design and function brand new from Taffys'
uh0qt0238t1k86ezg.jpg


Here is a hub I have from a 89-early 90's ktm same axle size as my axle guessing these early ktm front wheels will fit with minor spacer work. Bottom axle is my berg axle I have a complete KTM front wheel somewhere. I will check this when I get my forks back from the suspension shop!
dcyabje3ds5auwkzg.jpg
 
Last edited:
I have forks and triple clamps, along with front brake and front wheel, from a 2013 KTM 250SX on my '96 Husaberg FC600. The nice thing here is this opens these old bikes up to the possibility of running the 4CS, the Cone Valve, or even the air forks.

With some pretty heroic machine work, I was also able to adapt a KTM RFS 525 connecting rod to the engine in the same FC600. Thread here: http://husaberg.org/mechanical/16703-husaberg-ktm-hybrid-engine.html

Finally, back in the day when the 2000's were first coming out, I saw an older Husaberg (not sure what vintage) with the 2000 plastic adapted to it. The word at the time was that it took a lot of effort to make all the brackets and weld them to the frame for this to work. It stands out in my memory because the guy had the frame chrome plated when it was all done. It was UGLY!
 
Kickstarter swap

Tried my 1988 KTM MX500 kickstarter on the berg today! It Fits!
KTM 565 series motors 350,440,500,540,550 all have this Kickstarter.
KTM pictured with the rubber boot (1983 YZ490) keeps mud out better than nothing.
Slightly shorter,same splines and diameter. Made of steel and a good alternative to the stocker.These don't get all the free play. These are also left side kickstart and fold in nicely.
duem5ezekjwoitm7g.jpg

m7kyct9crlc38w87g.jpg
 
Update

Have been refreshing my new to me 99 501 Berg. This is where I'm at now.
d236dg4wniog2y17g.jpg


Fork brace rubber mounted holds Seal Savers tightly at the bottom.I used Marzocchi fork guards that look OEM had to heat gun to open the top to fit around the fork. The bottom piece of the Marzocchi guards the holder the top portion slides thru bolts right onto the brace. It was machined to accept these. The KTM 380 was what the brace was intended for just happens it used the same WP 50mm extreme forks.
Rear shock and forks rebuilt with new internal seals bushings and any other seals etc used in a typical rebuild.Coppersmiths of Akron, Ohio did all the work. Racetech Spring for my 200lb. Weight and a resevior kit with bladder and added a Pivot Works needle bearing kit under the spring to assist with binding and twist of the spring when compressing. Calipers and master cylinders rebuilt with all new components.
Have a clutch kit and Kickstarter sledge from Taffy yet to install and more new parts on the way.
A new OEM rear fender is on my wish list....Anyone?
zb3pqpelcgyfq927g.jpg
 
Any more on this build? Looks killer! Does the ktm kicker give you more clearance from the frame while on the down stroke?
 
Wow great work guys. I'd love to "restomod" a mid 90's Berg so will be following this thread.

Sent from my Nexus 5X using Tapatalk
 
Well only a little progress to add. I have added a Taffy clutch upgrade was surprised I needed to shim the clutch rod more than the supplied shim. The lever in the engine case went thru full range but was not opening outer clutch disc. Shimmed the inner basket to correct free play but there was no adjustment left on a brand new cable. I made a custom shim to take out the slack. I have had no luck finding new plastic.Guess it doesn't exist!
I have resorted to the quick fix instead of trying to sand and polish the plastic.
Vinyl car wrap! I have used it in the past and it holds up surprisingly well and colors are limitless. I am using yellow carbon fiber on radiator shrouds and side number plates as well as the Headlight plate. The gas tank is next but looking for something different. A lot cheaper than graphics for and FC model all I can find anyway.
Kick stand,chain guard,added and a new Dellorto carb. I considered an FCR but didn't want to try and match the air boots and throttle cable. Carb may need minor adjustments...came from Italy Dellorto jetted for the bike.
I still need to wire the headlight ,Tailight, turnsignals and aftermarket instrument cluster/ speedometer with hi beam,turn signal,indicators and temp.etc...and then I will be close to riding it.Also need to check valve clearance and timing!
Seat cover is also a used but to me better look than the original!
6e6hyyfhjb447slzg.jpg

6vgc9y6c5f2x24czg.jpg
 
I am going to try it on another plastic tank I have first to see. They make an air release vinyl film that allows air to escape to prevent bubbles when installing it. Maybe the fumes will pass thru? I will put up a pic of my test when it's ready!
You can also us an aircraft fuel tank sealer that coats the inside of the tank...essentially a liner that I have had success with on old 80's YZ's to keep the decals from peeling off. It should work for the vinyl car wraps too!
 
Last edited:
Haven't tried the kick starter yet!

Check the kick-start by hand with the spark plug out and make sure you've got clearance between the pinch bolt and the case. Could be expensive if not confirmed first.
 
I have wrapped both radiator shrouds and side number plates with a yellow carbon fiber look vinyl wrap. I use primer 94 a 3m adhesion promoter on the edges about 1/2 inch wide ....and on the backs wrap 1/4 to 1/2 inch which I use the same primer followed by a hot glue gun to help hold down all edges..... It's not pretty but nobody sees the back. I am still deciding on the tank color and I plan on making a set of my own "Husaberg" or "Berg" graphics from vinyl and super glue them to the existing vinyl.

lvlvysjq3olagk4zg.jpg
 
Last edited:
Tjs Wish you were my neighbor. I'd have some work for you. Anything tedious I hate doing.
 
Vinyl wrap update

Well I'm going with this scheme for now. I can always change it .I have only done this side of the tank.
3it8j4plbdl71d87g.jpg

I'll do more soon.
 
update

I'm done with the vinyl wrap. I still need to make a custom "Husaberg" graphic for the radiator shroud.
Lights and starter and all things electrical are next!
anomq5vp1bd82lvzg.jpg


x68cdl59qnuwbg7zg.jpg
 

Register CTA

Register on Husaberg Forum! This sidebar will go away, and you will see fewer ads.

Recent Discussions

Recent Discussions

Back
Top