2003 vs 2004 FE650 Reliability

Hi,

I think a 2004 Husaberg would be the better deal, there are some weighty improved details. But at last
and at least it is a question of price.
In my opinion the KTM is not a better bike. KTM know how to sell their product. And
winning a world championship is really the best advertisement you can have.
Here where I come from all the orange colours are almost gone, there are still a lot of KTM´s, but on the MX tracks and on races
only a few riders believe in KTM (4 strokes). 2 years ago the situation was reversed.
And even in my circle of acquaintances there are some people who had really big problems with their bikes.
Some of them changed to Honda.
But don´t misunderstand me: I don´t want to talk too negative about KTM. It´s not a bad bike, but it is as well not superior or the so called 4 stroke revolution. By the way: Honda also not.

best regards

hribman

Hi,

This far it seems that the -04 is better than the -03. The largest problem on the 02-03 engines is the electrical system. Main bearings have been an issue too but I don't know if these people with this problem has followed the maintenance schedule. The -02 is better due to the changes of bearings.
I know the FS650 has problem with broken valve springs but I don't know if it is similar with the FE.

Since I started to dig in this a few weeks ago I have noticed that the -04 engine is very similar to the KTM engine. Eg they have changed the rocker arm design to the KTM design since they have less problem. The main differences seem to be the housing, cylinder and the counter balancer. The mechanical parts seem to be similar and probably are but I have not doubled checked this. Only one Husaberg guy have told me that. Pure statistics in my club gives that the KTM bikes have less problem in general and that the owners are more satisfied. The Husaberg -04 model could change this due to the similar design as the KTM. There are only one FC in the club so they aren't popular in Sweden. There are much more FE models but you spend less time in the workshop with a Yamaha or a Honda but then you have a smaller bore. It is also easier to find parts to a KTM and sell the bike. The 525 EXC is a very popular bike and easy to handle.

Replace the rocker arm bearings is no big deal. You do it by yourself and it doesn't take much time. If you check the forum you will see that the bearings last around 45-100 hours. It depends on your riding condition. Download the manuals and the workshop manuals from the net and read them carefully. You can find the Husqvarna manuals at their web page and compare which bike you believe are the most fragile one.

At http://www.thumpertalk.com/forum/ubbthreads.php you can read about the other bikes. What I saw is that Husqvarna have problem with the valve springs. You shall also change these regular according to the manual.

About the electrical system; Scan this forum and check hirbmans solution.
I don't know if the -04 system works as well as the KTM system due to the heat since KTM run their in an oil bath if I am right informed. If you have the possibility you should ride different bikes to compare them. You will notice that a KTM and a Husaberg doesn't behave similar. Think carefully about what you want of your bike. Power, stability, maintenance, design, spare parts etc. You don't become happy if you need to wait for a part for weeks. Ask people around you about these but consider that they often don't tell the whole truth due to their feeling for their bike. It's similar with women or men; we don't want to see their weakness even if we have noticed them.

Good luck with your selection,
Mikael

Hi there again,

interesting dicussion, anyway.
From the mechanical point of view there is no doubt that a 03 model has nearly the same reliability than a 04.
Maybe, and that shouldn´t be understand as bad critics that a Husaberg becomes more and more a KTM, the crankshaft is now made by Rotax like the KTM one, and the cylinder head is very similar to the KTM one.
If this is an advantage or disadvantage I don´t want to value.
Surely, the engine has been improved every year to become more reliable, but since
2002 the mechanical side of the engine is very reliable. You can´t compare a sportmotorcycle like a Husaberg to a Honda XR 600. Obviously a XR 600 doesn´t need the care that a Berg needs. You have to maintain your bike carefully and regularily. It´s only allowed to rev high a warm engine, change your oil often, check the valve clearances and always ride with a cleaned airfilter and you will have much fun with your Berg!
From the electrical point of view there are some advantages. The 04 ignition is better. Mikst you´re right, the KTM Kokusan ignition runs in oil and the Husaberg one is running dry.
Some people had probs with the Kokusan when getting hot (me too), the soldering joints were smelted, but you can resolder it very easily. So the stator is repairable and you don´t need to buy a new one. A SEM stator is
not repairable, at least it´s not possible by using normal tools with normal skills.
So, if you get a 03 as bargain, then take it. I think you can buy a lot of SEM stators and Keihin carburettors for the money you saved.
I wish you many many hours of fun with your new bike.

best regards

hribman

I have to agree with hribman that an 03 should be considered. Resale value is a consideration though, so the 03 should be at quite a discount. I would expect around $1500 to $2000 dollars American difference. That was the difference here. There were only 150 03 models imported to North America according to Peter at HMS, and he sold 90+ of them. We had a reorginazation of the importer here in 03, hence the small numbers. Most people here don't know the details of an 03, and it gets confusing because most bikes sold in 03 were actually 02 models. A true 03 motor is the same as an 04 with the exception of sand cast cases. The accessories are another issue. The 04 has a Keihin Carb, Kokasun ignition, double breathers, bigger battery, and bigger starter. The reliability of the Kokasun ignition has yet to be proven in my eyes, but the bigger battery and starter was a much needed improvement on the bigger motors.
Dan

Hi doug,

there is a lot of truth in what you said. I can imagine what you felt when
riding a Husaberg compared to other bikes.
KTM copied the (old) Husaberg engine, that´s right, but they should have better been more consequent.
IF you have a look to both engines you´ll see that the Husaberg engine is more cleared up.
There is no doubt, KTM did a good job, their concept works well and most people are happy with their EXC - untill they ride a Berg for the first time (the original one) :wink: .
The Swedes have also done a good job, maybe a very good job, but the fact that Husaberg produced traditional a very light and sports orientated motorbike (a long time before the Japanese came) was the result that Husaberg aimed only at totally racers as buyers. It wasn´t a bike for everyday life.
Husaberg changed really quite late their engine into a more reliable object without changing it´s character or their concept.
10 years ago it was Husaberg who was often on top of the world championships but the Husaberg followers who rode their bikes for private use and just for fun were almost died out at the end of the 90´s.
The Husabergs were known as bikes who had the tendency to become damaged too early (mostly after wrong operation) - but the bad reputation was born.
There is nothing wrong with the dellorto carb, but it´s a bit old-fashioned and nowadays everbody wants to have a Keihin carb. It´s an neverending discussion about advantages and disadvantages of both.
We also discussed a lot about the differences between the SEM ignition and the Kokusan ignition here on this site.
You say you would save 3000 dollars, so my recommendation is: Buy the 2003 model. It´s a good one, you cannot do anything wrong with it.

best regards

hribman

You mention that the CR would be fine with the XR motor, but a new Husaberg motor is not like an XR motor. The 610 Husky was similar in power to a big XR, and the old 600\early 650 Husaberg was close although with much bigger HP numbers. The 04 Bergs with the new carbs and ignition respond much better to throttle inputs, but that is kind of going away from XR style power and closer to CRF450 style. If you like a smoother style of power, the 03 may be a better choice. Ask the old boy for a test ride of both?
Dan

i ride both xr 680 well tuned and crf 450,Since this year i bought a new husaberg 650. And the power ouput is simular to a crf,but when the Honda stops the husaberg is still reving and increases speed.

the only problem is high speed stability,over 170km/u the bike is wobbling at the steer,in supermoto races the topspeed is max 150-160km/u but for monobike it goes over 210km/u.

I ride it now for 1000km no problems at the engine,nothing for mechanical failures,i ride circuit(SM and Monobike),and cross

Hi,

yes, Husaberg is a virus. I´m already infected for 3 1/2 years.
Now there is no turning back! But I just enjoy owning a Berg.
Everybody I meet on a track or at an offroad event looks after me
and my bike. Some people are looking sceptically, others first only smile at me. But the one who laughs last, laughs longest. And that´s in most cases me!
All that makes me strong. I enjoy this situation.
I don´t hate KTM, too. But KTM is certainly overvalued. Now it´s time for Husaberg to come out of the KTM-shadow. It´s overdue for a long time.
Husqvarna is also not bad, but a few years ago they didn´t manage to catch up the leaders. The new model looks good, but here we don´t hear much about the Husky´s.

greetings

hribman

ciao tutti = hello all = goddag !

Newbie here, living in Italy, riding the monster 1000 2003 with 30000kms already in 1,5 years, but now ready to change this monster to Husaberg 2003 FS650.
I have the virus also, tomorrow I go see the bike with 1700kms on it.
I would do a straight swap. No money changed.

Please give me Your comments,

great site,

FinMoto

And immediately another question....

is the 2004 Workshop/Repair Manual good also for 2003 models because I did not find separate 2003 Manual from Husaberg.se ?

FinMoto

Look in the 'Download area 'Former Files' listing of the Husaberg.se site, all of the 03 Manuals are there.

Joe

hey Joe, thanks,
I totally missed the lower part, where the 01-03 Manuals were.
Thanks.

I see all here are happy of the 2003 model, even some changed are always done to newer models.

FinMoto

Did you have any luck downloading and opening the 03 Parts Manual? I have the 02 and 04 downloaded. Looks like in 04 they went to a completely different numbering system. Not sure what happened with the numbering system in 03 as I can't open the 03 manual after I download it.
Dan

I did save them to my disk first, as a 5217.zip ,

and them Extract it out from the zip to my disk, and it did open ok.

The 2003 parts manual is much better quality than the "scan like" Owners manual.

FinMoto