2009 model issues what has come up so far ???

20 hard hours took the full 12 hours to run in as per manual 1 small problem with the petrol cap breather hose replaced it and now perfection well almost it's not using any oil unlike my 08 450 exc my fe 450 09 is quite honestly the best bike ive ever had and ive had a new 1 every year for the last 10 years

on my 570, the countershaft seal and the right side radiator are getting replaced.

the profile of the thermostat housing is roughly triangular and the leading corner of it will rest against the backside of the radiator unless it is "clocked" during mounting, e.g. turn the housing in the hoses to prevent interference before tightening. mine crushed a bunch of fins and I saw a couple more at the dealer which were that way also. when my dealer requested warranty on it, the Husaberg techs thanked him for bringing it to their attention.

the countershaft seal was just leaking from the get go. nothing magic here.

Steve

for my business I have four '09 models, 3x a 450 and 1x a 570.
At this moment all four bikes accumulated close to 30.000 km.
NO real serious problems what soever. I can confirm the problem with the thermostat housing on the 570 and two bikes have a leaking counter shaft O-ring at this moment. I will have investigate but it's normally simply renewing a cheap O-ring. The entire gearbox is of KTM origin.

I made once the mistake of not putting the fuel connector correctly together which resulted in a bike erratically stalling from fuel starvation.
And on one bike the battery lead came loose with pretty much the same result. After checking the other bikes I found out that two bikes needed the bolt (ground, I believe)tightened.

I don't check the valve clearance as much as I used to do on the old models. Just a month ago we had to adjust on one or two bikes. Interestingly it was the exhaust that was off. It was caused by the shims which were cupped! (valve clearance too big!)

I did make sure that the cable boom next to the schocker doesn't touch. On one bike the cable boom was rubbing against it.

I find that the exhaust is "hanging" a little to the inside. With a 120/100x18 it tire is touching the inside of the exhaust. That's a shame because the bike is near to perfect.

09 570. 23 hours. Countershaft sprocket seal leaking from the beginning. Replaced the seal, no problems. The occasional flameout, maybe 5 total. none in say the last 10 hours. Rear wheel grazes the muffler, shimmed the muffer out, no problems.

So far I'm very impressed with the reliability,durability and overall build quality.

Gonna have a look at the thermostat housing tonight.

Cam chain adjuster on mine is failing. Just replaced it in my 08 450EXC-R with an after market one from the States now it looks as though I'll need one for my 09 FE450 too..

Other than that & fuel range I cannot fault this bike - It's Awesome!