09 fe570 with 610 + cam

Gazza said:

Here is our team issue log so far after about 50,000km rallye racing the new Bergs

3 x ’09 570’s for 2009 Condo 750 rallye @ 1,000km ea - top bike was 6th outright
Issues were - fuel injector blockage x 2 (one just after the event)

3 x ’09 570’s for 2009 Yilgarn Rallye @ 800km ea - top bike was 3rd outright
Issues were - fuel injector blockage x 1

6 x ’09 570’s for 2009 Safari @ 4,000km ea - top bike was 7th outright
Issues were
head gasket leaking x 5
conrod big end bearing x 1
piston seize x 1 but this one also had the head gasket go big time so was linked
subframe mounts crack x 1 this is the metal tag on the frame where the subframe bolts to

1 x ’09 570 for 2010 Dakar @ 2,500km
No issues

1 x ’09 570; 3 x ’10 570; 2 x ’10 450 for 2010 Safari @ 3,500km ea - top bike was 4th outright (this was the ’09 motor)
Issues were
head gasket leaking x 2 solid copper TR ones, went back to OEM with Hylomar gluing
conrod big end bearing x 1 ’09 570 motor
TPS sensor x 1
engine oil sight glass leaking x 1 but not a critical one
clutch cover gasket leaks x 2 (weeping only)
subframe mounts crack x 1
stator cover weeping x 3

Fuel injector blockage issue has been cured by using the Profill fuel pump filter kit http://www.profill-australia.com/ coupled with a CanAm external inline fuel filter part # 709000100 placed in fuel line at QD junction before the injector, so it has 3 filters in total, since doing this no injector issues

Head gasket leakage issue has been cured by using Hylomar gluing the laminates together and on the gasket surfaces to both head & barrel…………BUT must keep an eye on the radiator water levels to make sure all is ok

’09 conrod big ends…………..don’t know re this one, except the 2010 motors haven’t done it, it has occurred twice at about 2,500km, both with early 2009 production run motors, so ???

TPS issues, word is it affects KTM’s such as the new 350SXF as well but not heard of it before on the Bergs till this one failed


Other known issues

They will pump oil into the air filter box from the crankcase breather unless you block the vent and re-route the vent hose to the back lower part of the bike

The fuel pump has gone on a couple of local bikes but not any of ours

Fuel tanks need to be flushed to remove residue before use

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Gazza said:

bushmechanic said:

On behalf of a few lurkers I know I would like to Thank you Gazza for sharing your hard earned findings

since the safari came through there is a bit of interest in the 570 and this kind of stuff is exactly what they are looking for.


I keep telling them the 628 should be more robust but they don't believe me :lol:

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well tell them from me the '07 & '08 FE650's were a very stong bike & engine, here is the issues log we had after 36,000 km rallye racing

'07 Safari 2 x '07 650 @ 5,500km ea - zero OEM issues, I did a motor on day 2 due to the added external oil cooler line breaking and dropping all the oil , but no OEM issues at all top bike 8th outright

'08 Condo 750 2 x '08 650 + 1 x '07 650 @ 850km ea - zero issues

'08 Safari 3 x '08 650 + 1 x '07 650 @ 4,500 km ea - zero issues top bike 10th outright

'09 Condo 750 1 x '07 650 @ 800km - zero issues

'09 Yilgarn Rallye 1 x '08 650 + 1 x '07 650 @ 500km ea

'09 Safari 2 x '08 650 @ 4,000km - zero issues top bike 5th outright

so after 36,000km rallye racing over 3 seasons we never touched a single motor or bike re OEM parts breaking, and thats with 3 top 10 Safari finishes :cheers: damn fine motorcylces, our mechanics had it easy

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bushmechanic said:

you want those rockets on your new rod as well ?

head gasket looks familiar

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