Early Berg Enduro to Supermoto Help

Well I got my LC4 cush hub in (still waiting on the carrier and rubbers.

I slid it on the axle and put it in the swinger and I can see where the chain will be out of alignment.
Looks like I can mill some off the outer surface of the caliper carrier and correct this and still keep the rear rotor in line with the caliper. No biggie.

I have a friends DRZ400SM at my house and I'm sure I can make the front rotor work with a little massaging on the ID of the rotor. I might even pick up a 320mm DRZ rotor to use.

I'm debating on what front caliper I want to use. Since I'm making my own stand-off I have a lot of options. I'd like to use the stocker to make swapping easy, but I'm worried about that little guy fading on me.

I live 20 min from Deal's Gap, so I need to make it right.

BTW, I'm not threadjacking, or not intending to, I'm just doing the exact same thing and hoping we can share info.

So I have pretty much everything sorted, just waiting for some parts to get in.

I had one question though. How wide of a rear rim/tire can you run on this bike?

I ordered a 4.25" rear rim to use a 150 tire and now I think I could possibly go 5" with a 160.

Anybody know?

I have a lot of pics to get together.

Well, I still need to upload pics, but:

I went with an early KTM Duke hub for the front.

It's 17mm axle, and the KTM hub is easier to find disks for than early Bergs (yes you can modify a DRZSM rotor, I have one sitting here), and if you haven't already discovered, the original front Berg hub is a non-conventional spoke pattern. That makes it a PIA to get spokes made and rims to fit correctly. Not impossible, but you have to ship your hub to Buchanan's to have them custom cut spokes.
Instead, I just ordered a spoke kit (from KTM) for the duke hub and I'm lacing them to Warp 9 rims.
My local KTM shop also just happened to have a new Ferodo 320mm floating rotor that fits the Duke hub, and I got it for a song. He also had a relocator for a brembo caliper but it's the later wider bolt pattern for the fork leg, no biggie, I'm just gonna drill and tap a hole for the early mount pattern. Both the relocator and rotor have holes for mounting a Trailtech speedo sensor and magnet with retainer clip, respectively. It's like it was all mean't to be.

On the rear I used an SMC/any big bore KTM cush hub P/N 5841001034491, and picked up a sprocket carrier and rubbers of eBay. If you do use this hub note that there are 3 different sprocket carrier part numbers for this hub as the carrier bearings changed throughout the years and are dimensionally different. Depending on which sprocket carrier you use it may require a different width spacer between the sprocket carrier and the hub to keep the carrier properly seated when the wheel is tight.
Even though the P/N for the cush hub is the same for all years it usually ships with the later thin spacer, and you will need the order the earlier thick spacer. I used the earlier thicker spacer with a '95 sprocket carrier.
EliteKTM has an awesome parts fiche and I used that to determine which spacer I needed.
I also ordered a rear spoke kit for the SMC wheel (the earlier wheel that uses 4.25" rim) so I shouldn't have any problems lacing it up to a 4.25" Warp 9 rim.

I ended up milling ~1mm off the inside face of the rear caliper carrier where it mates to the hub. This gave me more clearance and lined the rotor up dead nuts in the caliper carrier. I milled about ~2mm off the outside of the caliper carrier and the hub dropped in. **BUT** I didn't need to do that. When I tightened down the wheel it seated the sprocket carrier in the hub more than I could do it by hand and when I loosened the axle the gap at the ouside of the brake carrier was about what I had milled off. No sweat, I just slipped a stainless washer in there to take up the slack.
Chain alignment is correct and the rear caliper is floating within range of the carrier and the brakes work. It was EASY.

I should have the front hub and spokes in the next few days so I can tackle the front brake setup and wheel spacing.
Then the rims should be in about a week after that so I can lace it all up.

I'll see if I can't get pics posted up today.

Here you go.

Found this at the local KTM shop. This is what happens if you don't want to run a cush drive.



Milling:



Fitted:

Rotor and relocator:



Rear spokes:

As far as the hub issue, it's the angle and order that the spokes exit the hub. It's actually kinda backwards from standard hole patterns. From a glance they are the same, but they are not.
Like I said, it's not impossible to lace it up, you just need to send your hub to Buchanan's to have spokes made with the correct bend in them to go from a non-standard hub to a standard rim. I know of another guy on here (fredcp) who has done it.
All I did was kill two birds with one stone. I opened up my brake options with a common bolt pattern and corrected the spoke issue using a duke hub.

You may have an issue with the rear spokes fitting if you order Buchanan's WITHOUT sending them your hub. The issue is the cush side. If you look at the hub the flange on the cush side is larger diameter than the brake side flange, not symmetrical like most hubs. And the spoke bend will be different. When I talked to Angel at Buchanan's he told me it's best to send the hubs if I was going to have spokes cut due to the fact the flange is different. If not I may have "banana spokes", not good.
As above it's not an issue if you send them your hub, they can make the correct spokes.
So instead of messing with that I just ordered the spokes from KTM that I KNOW will fit the hub and the SMR rim. The cost was about the same per wheel (maybe even a little less.)
Just depends on how you wanna skin that cat.

Hey Bergini, I may have some questions for you regarding your rad fan/thermostat setup. I stumbled across your thread a while back. I dig that setup.

Well it turns out the relocator I have will not work, there isn't enough meat on it to drill and tap another hole where I need it.

BUT, Motomaster has a relocator that FITS OUR BIKES. I'm waiting to here back from them on it.
The Motomaster P/N: 211012

I also got the Duke front hub in, I'm just working out spacing. It should be pretty easy.

Rims ship out tomorrow, so there's a SLIGHT chance I can have this thing on it's own weight in supermoto trim by NEXT weekend.

Why can't I just order a new 18 front rim an pull my hub out of my bent off road wheel an just bolt it on I'm not a big time road racer so I think the stock brake will be fine for me but why can't I do the wheel swap an put street tires on my bike an be done?

It's been covered before that early Husaberg hubs have an unconventional spoke pattern, so you will have to have custom spokes made/rims drilled for the stock hub to work (Buchanan's.)
I know of a guy on here that has went that route with 17" rims and it worked out fine, he did however need to send his hubs to Buchanan's for sizing.
It's not impossible, and not all that cheap, but it's not as straight forward as you would imagine.

Also, I got a LOT done on my bike, wheels laced, tires on, etc. I'll get some pics up.

What size tires do u run ?

I was told today that a XR 650 wheel fits the berg it has a 17 mm axle an all u have to do is cut the spacers down to fit perfect this was done by rob at warp 9 wheels he was a wealth of Info on bergs way more than buchannens

My '98 FC600
On Talon hubs and Behr rims, no cushdrive been fine street riding for the last couple of years. Has 120/70/17 front and 150/60/17 on the rear but chain clearance is small. Tomorrow i am trying a 140/70/17 rear