Let's get one thing straight right off the bat: when building a project bike, it's not about slapping on all the fancy parts you can find. For our 2025 Husqvarna FE501s ADV-lite bike build, we wanted to make a bike focused on extended travel rather than just day rides. We've seen lots of 500cc dual-sport builds, in fact we did one in 2021, but there are better options now. A 500cc single-cylinder needs a lot of oil changes and high revs on the road, which can be a pain during long rides. Our goal with this 501 was to improve an already great dual-sport chassis and make it better for long weekends exploring BDR Routes and occasional pavement use.
The suspension on the FE501s has always been plush from the get go and has always been great for dualsport usage, so we kept it as-is. While we have modified suspensions for other bikes before, the stock setup works well for this build. Keep in mind, the goal here is to create a bike for exploring over a few days, not for racing in the desert or tackling tough enduro terrains all day long.
The Superlight tower from Aurora is an incredible feat of engineering and design. It is the lightest 3D CNC tower created by their factory. The development was based on many hours of riding data collected over the years. Despite being light, it is structurally stable, and its center of gravity is even closer to the bike's headstock compared to their other designs, so riders won't feel the addition of a navigation tower. There are several light options, but we chose the Baja Designs Squadron Pro's.
The rally kit is perfect for riders who want to explore trails without dealing with a bulkier setup or integrated side panels. It's unique because the CNC tower is the lightest of its kind—the main tower is just 848 grams! The screen is made of 4mm thick PET material. Its aerodynamics have been perfected, and thanks to the unique adjustable brackets, you can change the way it protects you during long journeys.
The kit comes pre-assembled! Everything is assembled for ease of use and reference. The Aurora team is available to help almost 24/7 and can be contacted by email or text via their website to ensure smooth installation. The 3D printed air scoop keeps your lights cool during hot rides, improving reliability in the long run.
What's included in the kit:
- Aluminum Billet Head Clamp
- Aluminum Billet Navigation Tower
- Adjustable Rally Screen
- 1/4 turn bolt fasteners and Dzus receptors
- Rectifier bracket and extension cables
- Ultra-hard 3D printed resin air scoop
- Two RAM® ball mounts
- OEM Speedo relocation bracket
- CNC Polymer Cable Guide
* When adding lights, the kit comes with the necessary hardware and wiring harness.
We extended our bike's range by installing the Acerbis 3.9-gallon tank. The installation was quick and easy, thanks to the OEM quick-release fuel hoses. With an additional 1.7 gallons of fuel capacity over the stock tank, we were hoping to achieve a range of more than 165 to 195 miles on a full tank, depending on the terrain. In addition, we added an Acerbis skid plate. It was easy to install and provided the level of protection we were looking for.
Stock tires were replaced with a set of Dunlop D606 tires. These tires were an excellent choice for the bike's intended use. They offer good grip off-road without feeling unstable on-road and are D.O.T rated. Thanks to the 501's lighter weight, these tires instill confidence on hard surfaces, and they are durable enough to handle highway miles without wearing out quickly.
The stock 501s lacks a bit of a punch due to the restrictive muffler, so we decided to enhance our bike by adding a new LeoVince stainless steel slip-on muffler. This not only improved the sound, but also reduced the weight of the bike. Additionally, the muffler provides some extra power gain and is USFS approved.
Depending on the ride, we'll use either the Mosko Moto Reckless 10 or Reckless 40 luggage system on the 501. The Reckless 10 is for big day rides, while the Reckless 40 is for multi-day trips. With the addition of Mosko's Gnoblin, mounting the Reckless luggage is fast and easy.
The 2025 Husqvarna FE501s is versatile and can be built for different roles, making it great for various terrains and adaptable for future changes.
Build Parts:
- Aurora Superlight Rally Tower Link
- Mosko Moto Reckless 10L Link
- Mosko Moto Gnoblin Link
- Outback Motortek Crash Bars Link
- Trail Tech Voyager Pro Link
- HammerLEDs Turn Signal Kit Link
- DDC Racing 45 Tooth Rear Sprocket Link
- Dunlop 606 Tires Link
- LeoVince X3 Evo Slip-On Muffler Link
- Asterisk Universal Heat Shield Link
- Cycra Pro Bend Ultra Handguards Link
- ODI V2 Lock-On Rogue Moto Grips Link
- Acerbis 3.9 Gallon Fuel Tank Link
- Acerbis Skid Plate Link
- Acerbis X-Brake Disc Cover Link
- Acebis X-Brake Mounting Kit Link
- Twin Air - Air Filter Link
- IMS Core Footpegs Link
- TMBR Moto - -Back Country Titanium Seat Bolt Link
- Doubletake Mirror - Dual Sport Mirror 2.0 Link
