Thanks to everyone for your help / ideas.
I just downloaded the microfiche or pdf version for both 2011 FS and FE 570 and compared every nut and bolt on both bikes. ya, you would have thought somebody on here would have already done that. They are not as different as one may think. They may be set up different, but the components are almost the same.
I can buy either 2011 FS or FE 570 for the same price.
I won't go over every item but try to cover some of the important differences. Suspension uses basically the same parts but different springs. ( dealer has a choice on different springs depending on rider set up when ordering the bike so you may want to order vs paying for springs afterwards ) Also, just because you rode a SM and thought it was stiffer than the FE you tested, doesn't mean the internal valve was different. Just set up different. The SM may use a different clicker adjuster from 2004 and the FE may use one from 2008 but they serve the same purpose which is selecting a setting. They switched to different dust seal manufacturer and guide seal the best I could tell on FE but I have not read of any problems with the older seals. Some parts on FE/FS were from older models and some were from newer models, seemed to balance out if it makes a difference what model year the part was originally for. They listed 2 different model years of the same part in a couple places so maybe your bike came with that part from 2009 and your buddies came with 2004. All in all I could not find different suspension parts that would change the set up options, only the travel based on adjusting tube length. If anyone can prove there is a difference between the two other than springs which you should change for rider set up, please let me know. 3/4" less travel on front and 1" less travel on rear FS model is not going to hinder somebody play riding in the dirt. There has to be a reason why they reduced the FS travel and if your converting from FE to FS you may want to find out. But if your more about dirt riding then get the FE.
The triple clamp on FS is larger than on FE but will the average rider notice a difference ? The FS uses larger front brake so the caliper and axle clamp bracket on forks are different. If you get the FE, an adapter can be added to extend the caliper out for larger brake disc if riding on street/track. If buying FS, you would be better off using a 310mm brake disc on dirt wheel set because you can't make the bracket shorter on FS without removing from fork tube and installing a different axle clamp and bracket like FE type.The FS brake is going to be stronger and provide better feedback but if your just play riding the bike in street form the FE may have enough brake or could be upgraded. I priced just the FS caliper and nothing else for almost $700 U.S. on the KTM website. Makes me wonder if the FS wouldn't be a better choice since I'm not racing dirt just because I can get the expensive brake set up for same price. Less chance of rotor damage just playing in the dirt and I would still have the better brakes for both riding styles. Just remember if your doing 80% dirt and not really needing the FS brakes, your still riding with extra weight up front. Not much but rebuild kits will cost more also if you keep the bike long term. Some dirt riders have upgraded to the bigger brakes because they like the better feedback. I expect they ride more open high speed areas vs tight single trails. Depends what you like!
The FS front brake lever, res. and caliper are all same as street bikes and the FE front is same as standard dirt bike. the entire rear brake set up is exactly the same on both bikes.
Wheels obviously are different. If you plan to ride on the street a lot the FS is already set up with cush drive and brakes for that. Picking up a complete set of dirt wheels that don't need the cush drive may be a little cheaper or you could go cush drive and use components from FS wheel set. Seems if you start off with FE and set up for street, the cost may be a little higher if buying new. But there are always deals to be found if not in a hurry.
My goal is to set everything up so all I have to do is drop out the one wheel set and install the next with same brake disc. and chain. Turn the clickers and ride. It may not be perfect, but I am not racing and the few seconds difference in handling won't matter. If doing a special track day or dirt ride I would take the time to perfect the set up if needed but for general use, it should be fine with a 565 cc engine. With the wind hitting me head on during street rides, I won't be planning any high speed trips. That gets old real fast,in my opinion.
If going from FE to FS setup, the wheel is offset and you may need to space the exhaust out a bit depending on wheel size. Going from FS to FE the wheel is not as wide. That is why the FS comes with exhaust can spacers that the FE doesn't have. Another minor difference...
Fender and fork guards are different, graphics and color is different and if riding in mud you kind of need the longer front fender so you would want to have both either way if converting. They both use fender spacers from different past years but look to serve the same purpose. This is what I was referring to about different year parts but they do the same thing.
That is pretty much it. The rest of the bike is exactly the same. Give or take a zip tie here or there. FS uses a 5mm longer exhaust bolt because of the spacer to move exhaust farther out but it is the same size bolt just longer. If you were converting the FE to FS set up, you would have to buy the longer bolts and spacers.
Bottom line is you should tune the suspension for each rider so that really doesn't matter either way. Your going to spend about the same on wheels if you shop around but maybe a little more on FS style wheels if you start with FE.
The bigger more expensive front brake is really the deciding factor if you plan to do double duty with the bike. I know there are play track days in my future and trips to the mountains so the FE would need an upgrade to make me happy. I have no plans to race dirt any more and therefore feel I can keep from damaging the expensive FS brake setup while still enjoying better brakes. If that changes, a disc guard is still cheaper then converting FS to FE style brakes.
Hope this helps narrow the which one question down a little. And if anyone can offer info that proves there are other differences not listed on pdf, please let me know.
There should be some manufacturer discounts over the next few months before the 2012 models hit. Leave me one!
Jon
