• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

SWM Motorcycle

ray gamache

ray gamache

Husqvarna
AA Class
Well I decided to purchase a new SWM RS500R. First, great bike and I am happy I chose this bike. Wanted to share the upgrades that really helped to make this bike work for myself.

The first task was to address the weight. I wanted to remove all of the "dual sport" accessories including the metal hand grips and mirrors (I replaced the metal mirrors with plastic acerbis mirrors)

Next I removed the dual exhaust system and replace with a Vance and Hines spark arrester muffler. I decided to purchase an exhaust from a 2009 CRF 450 and modified the exhaust pipe on the SWM just in front of the Y pipe and cut/welded a new pipe to adapt to the SWM. The reason for selecting the CRF 450 exhaust is the low price where the spark arrestors are being sold for about 140.00

In addition to address the weight I replaced the lead battery with a Li/ion battery which also dropped down the weight.

Both the skid plate and radiator guards were purchased through E-bay brand new (enduro engineering) both were around 65-75 dollars each.

A key issue is the flame out issue due to the lean mapping from the factory. This was remedied using the JD Jetting 6x fuel injector mapping system. This is a little pricey ($250) but worth it. This system was designed for the te 510 fuel injection system but works on the SWM. If you want the mapping please contact me and i will share.

The gearing was too high on the SWM so I replaced the rear sprocket from a 46 to a 51 which worked well for the trails.

I decided to also include a rekluse auto clutch. The only one I can find was a 2006. To install a 2006 you will need earlier model clutch discs, hub and basket. The components can be bought new or used at reasonable prices.

I removed all of the blinkers and tail light systems and replaced with smaller LED lights which both reduced the likely hood of hitting obstacles and reduced weight.

Lastly the bike is tall (I am 5'10") and I was able to purchase a used Kouba Link suspension lowering system (1.5" lowering). There are a lot of negative comments about link lowering but I followed the instructions on the Kouba Link website and have been very pleased with the performance.

With the listed upgrades the bike handles and runs great. The JD mapping system worked great and flame-outs are a thing of the past. The suspension was amazing and the bike did not feel heavy.
 
Great post, thanks. I also have a 19 rs500r. Were you able to lower the RPM with that jet kit? My bike's idle was set high which makes for a lot of noise and clutch work on the trail. I have the single exhaust and my dealer did the mapping updates and the O2 sensor removed; it pops quite a lot on decel. I am planning all of the same mods you made, but I want to address the engine and gearing first. How many links is your chain with the 51 tooth sprocket? I love the bike! So much power!
 
There should be an adjustment screw to lower the idle. The jet kit fixes the flame out that occurs at low throttle stalling the engine. There are three mappings available for the SWM from the dealer. I asked for the richest map and then used the JD kit to raise the pilot fuel level and also what would be equivalent to the fuel pump by one setting (3 to 4) and the bike has been running well.
 
ray gamache said:
There should be an adjustment screw to lower the idle. The jet kit fixes the flame out that occurs at low throttle stalling the engine. There are three mappings available for the SWM from the dealer. I asked for the richest map and then used the JD kit to raise the pilot fuel level and also what would be equivalent to the fuel pump by one setting (3 to 4) and the bike has been running well.
Click to expand...

OK, food for thought on that jetting. I also wondered how many links I will need for that taller rear sprocket.
 
Probably about 3-4 links (guess, i never counted) I bought a new chain as I saved the old sprocket and chain for desert rides.

One point to be made from previous post, the JD kit (for FI) makes the bike run "like a Bat Out of Hell" but fuel consumption increases.

One other note to be made in my recent changes, I bought a used 2008 510 3.1 gallon tank for the SWM and it fits well but you have to purchase a Husky seat (Ebay has folks from Italy selling new Acerbis Rubber Seats for a reasonable price) and shroud plastics from 2008 -2010 Husky

Still love the bike and the suspension is really good!!
 
I have a local shop just pick up the swm. Went to look and they look really nice. I have a ‘15 beta 430rr since new but I’m loading up miles on it even with my husky as a back up. As much as I like my beta the price is right on swm especially with the suspension that comes stock. And I like everything you’ve had to say. How often do you ride?
 
John, I try to ride most weekends and recently did 3 day trip in Death Valley. Some of the plastic is not as good as Acerbis but the bike is solid and more importantly most parts interchange with the 2010 husky 510. The suspension is very good, bike is a little more porky than KTM 500 but it does not bother me. Lastly there seems to be negotiation with price
 
ray gamache said:
Probably about 3-4 links (guess, i never counted) I bought a new chain as I saved the old sprocket and chain for desert rides.

One point to be made from previous post, the JD kit (for FI) makes the bike run "like a Bat Out of Hell" but fuel consumption increases.

One other note to be made in my recent changes, I bought a used 2008 510 3.1 gallon tank for the SWM and it fits well but you have to purchase a Husky seat (Ebay has folks from Italy selling new Acerbis Rubber Seats for a reasonable price) and shroud plastics from 2008 -2010 Husky

Still love the bike and the suspension is really good!!
Click to expand...


Thanks for replying back. I picked up a larger tank too, I will be fitting it up soon. I have not bought the chain and sprocket yet, but will do. The engine seems to be running great with the tune that the dealer did for me, Upstate Cycle. I love the bike and agree that the plastics are too brittle, but boy is it fun!
 
The stand out is the KYB suspension it seems to work very well. I was told that there were only 3 mappings available. I asked for the richest of the three but still once the bike is warmed up it flames out when you let off the throttle. I was told but have not tried to adjust a setting on the FI system. Its not the idle but another setting that affects the low end fuel mixture. For shorter trail rides the JD kit is great but when I unplug for desert rides the flame out rears its nasty routine. Glad your having fun. Just an FYI I fixed the plastic issue by purchasing 2008-2010 husky plastic (really cheap right now) and there are decal sets for around 50.00.
 
Ray, the controller you used was for a 2010 TE510? I have a 2019 RS500R and the flameout is killing me, if you are running hard and go to slow down blipping the throttle to match rpms for downshifting it will do it about every time. I also am interested in upping fuel tank capacity but am concerned with using a husky seat because my seat has that pointed rear near the fender, did you change all plastic?
 
Yes use the jd fi kit for the 2010 te510. This will fix the flame out and give you a lot more power as mentioned previously it will drop you your fuel efficiency. I just purchased a fuel mixture sensor and will try to make a setting that gives better fuel economy and still removes flame out. You will need new plastic and I recommend a new seat. I bought an acerbis rubber seat from Italy though eBay for about 130 US dollars. I have made a lot of modifications that I will share shortly
 
I’ll get around to it ina month or so. I have already did seat concepts seat and g2 throttle tube. I am waiting to decide if I am going to order the arrow exhaust or not. I’m a little unsure because I want to keep noise down and retain spark arrester. I would love to find a clapper te 510 as a donor bike and try the husky single exhaust first but they are hard to find other than people parting out on eBay trying to get rich. I like the dual exhaust for function but ditching some weight up high and on the rear would surely improve feel and handling.

I really wish I would’ve bought the sm version and got the 300 for dual sport needs, I think that would’ve been a better fit for me.

Looking forward to your pics
 
Well a followup on the JD jetting 6x, I have had good luck with it so far but decided to take it to a bike shop with a dyno to properly tune the tuner. The dyno will measure horsepower and fuel mixture. Ideally the bike should maintain a mixture fuel/air of 13. With the original factory settings the low and mid-range is VERY lean and the top end is a little rich. For the low and pump setting the tuner had to be set to the maximum richness and the top end was leaned out a little. Having the bike put on a dyno removes the unknown of correct settings. I am happy to share but I may be off unless you use the same exhaust (Vance/Hines 2009 CRF450 w/spark arrestor). With these setting no more flame out and great power.
 
So you maxed out the tuner on top of the “rich map”? I’m still debating on what I’m going to do, besides my wr426 sm needs some work done before I put it for sale and I’ve had a bunch of parts for my Xr650r waiting to be installed. There’s a post on the aprilla forum between a new owner of sm500 and a worker from af1 racing that tuned his bike before delivery, supposedly it made close to 50hp with Arrow and map only.
 
That is correct, the bike from the factory is extremely lean down low (for the rich map) and slightly rich on the top end. I cannot comment on my actual horsepower the dyno showed around 49 HP One other piece of information I was given was that many of the fuel injector mapping devices are actually the same. It appears that one company makes many of these mapping devices and are relabeled by companies such as JD Jetting.
 
Thanks for letting me in the club. I have a 19 SWM RS500R that I'm learning about now. I've only been able to get 2 rides on it before winter hit here in the Midwest. I'm anxious to learn more to get the fueling correct, as it was seemed all over the place. It flamed out on me a couple times, starts hard. I have a feeling this thing is fickle, and hope to get it sorted out. A few things have bothered me about it. It had 3 "dead" spokes on each wheel when I was bored and checked the wheels. So loose, they had no tension. I also found the upper triple clamp to be not tight. I could flex the bars forward and backward. I came from a Honda CRF250L, so this bike feels quite different than what I'm used to anyway.
 
Jumpn Issues related to spokes are something that should be covered by warranty. I have heard that SWM wants to make things right if you have issues. The SWM is a European style bike and the bike is heavier than your Honda. I recommend the JD jetting Surge 6x for 2010 Husky te 510 for fixing the flameout.
 
ray, the SWM is actually at least 30-35 pounds lighter than my CRF250L. I trust my dealer will make it right. Did the JD kit help smooth out all around the rev range, or just the open to closed throttle flame out?
 
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