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Home » off road bikes » EnduroCross Up Close – Factory Bikes – Dirt Rider Magazine

EnduroCross Up Close – Factory Bikes – Dirt Rider Magazine

By: jesse ziegler

Monday, November 16, 2009

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<p>A new discipline of motorcycle racing is shaping up right before our eyes. The Geico Powersports AMA EnduroCross series is still, after five years, like nothing else. It’s more brutal, more technically challenging, more condensed and much more unpredictable than any current motocross or off-road series.To quote Am-Pro Yamaha’s Jason Raines, who made his first main event appearance this year at the Florence, South Carolina, round, “In EX, anything that can happen, usually does happen!”It’s this unpredictability that has factory teams scrambling to find the magic setup to handle all that EnduroCross throws at its rider. We cruised the pits in South Carolina to see just what makes the EX bikes go. Enjoy.
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<p><strong>Factory KTM</strong><strong>Taddy Blazusiak #111 KTM 250 XC</strong><br/><br />
Taddy Blazusiak is the man to beat. Even though Monster Energy Kawasaki’s Ricky Dietrich holds the #1 plate, Taddy has a generous point cushion and, as of press time, a three-round undefeated streak in 2009. His bike of choice is the KTM 250 and is easily the most factory machine in the series.1. Taddy’s engine is factory-cased in magnesium but maintains a close-to-stock 250 configuration inside The extreme race ace told us his bike has a lot of power but he wouldn’t call it snappy. It’s full of boost and torque and reacts very quickly but is always controlled. The motor, according to Taddy, is much different than a standard 250 XC inside, so no power-valve setup tips for you KTM lovers here. Sorry. There’s also no E-starter. The carbon fiber petcock guard is sleek and protective but constitutes the entire inventory of protective parts around this engine. If you watch Taddy ride, you’ll understand why he forgoes the excess weight of skid plates and other guards-his skills allow him to go over, not through or into, rocks and logs.2. A huge 52mm KTM WP SXS factory fork rides up front on 18mm-offset triple clamps. Taddy doesn’t need much high-speed stability in the bowels of an EnduroCross course, hence the tight offset of the clamps. His suspension setup is almost identical to an aggressive, somewhat stiff enduro setting except he likes just the very initial part of the stroke to be softer for EnduroCross. Many people assume Taddy’s setup is ultra-springy causing him to bounce, but he says his riding style (à la trials) makes it look like he’s bouncing as he moves the bike to set up for obstacles. Both the front and rear stay tall in the stroke but give on the harsh impacts.3. The factory WP fork feet feature a sleek machined caliper mount on the brake side. Note the safety wiring of the brake pad pins-protection and longevity are key in EX.4. The other side of the factory KTM fork setup shows off the forward-facing pinch bolts and silicone-filled axle. Water crossings are guaranteed.5. Taddy brings a lot of his own sponsors to his race program. One of those is Akrapovic Exhaust. While the expansion chamber appears shiny stock on his machine, this titanium Akra silencer, while production looking, is laser-etched custom for #111.6. Precise tire grooving is an art form. As you’ll see on other bikes, it’s easy to hack up a tire. The dissected knobs flex, bite and grip the mix of EnduroCross obstacles much like a trials tire (which is banned). Taddy only grooves his rear tire like this to drive him through and over obstacles. Inside front and rear, KTM uses foam inserts in lieu of tubes or Tire Balls. The inserts aren’t stock density, though. To drop the “pressure” and allow the tires to squish around the terrain the team “does stuff to them.” We’re guessing that means drilling holes in the foam, but they won’t tell us for sure.7. EnduroCross requires protection-as long as it doesn’t compromise controls. In order to fail-safe the two, Taddy trims his flag-style guards so they can’t pinch his levers back.
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<p><strong>Mike Brown #311 KTM 250 XC-F</strong><br/><br />
At press time, Mike Brown had only raced EnduroCross for three races and already he’s a shoo-in to qualify for the main event (no small feat!) and a serious podium contender. Brown is sitting fi fth in points at the halfway mark. The former MX champ is looking for his breakthrough ride, and dialing in an EX-specifi c race weapon is part of that. Here’s what his ride is all about.1. Brownie goes thumper for EnduroCross. Starting out as a 250 XC-F, his factory KTM goes through a serious transformation. It’s stuffed with 280cc of displacement for more ultra-bottom torque and power. In a weight-saving effort the kickstarter assembly is completely removed from outside and inside the motor. More, the team transforms the bike into a three-speed, although they won’t tell us which gears they keep in the box. FMF handles the pipe duties, and a beefy Hinson clutch cover takes EnduroCross course obstacles head-on while protecting some off-the-record, top-secret, non-sponsor auto-clutch components.2. Out front, Brown uses a mid-to-soft-terrain Euro-spec Enduro tire. EnduroCross promoters have been using more sand sections, and with those and the water crossings, corners can get slippery and loose so the front tire choice makes sense technically. Most teams still run hard-pack tires.3. This sleek KTM glide plate protects the frame and delicate water pump from the nasties.4. Every competitive pro-class EnduroCross bike runs an aftermarket bottom chain guide. T.M. Designworks units, like this one on Brown’s bike, are the most popular. Notice the rust on the front mounting bolts. You won’t see that on a supercross bike. EnduroCross is hard on even factory-prepped bikes, and budgets don’t allow for supercross-like rebuilds.
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<p><strong>Monster Energy Kawasaki</strong><strong>Ricky Dietrich #1 KX250F</strong><br/><br />
Ricky Dietrich is the defending EnduroCross champion. He was also the top American at the 2008 ISDE in Greece and the 2008 AMA Racing Athlete of the Year. This year you might have seen him grabbing impressive finishes in the Lucas Oil Motocross series as a member of the factory Kawasaki motocross team. To say he’s rolling in talent is an understatement. Suffering a foot injury at the second EnduroCross round had him sitting out of South Carolina, but he’ll be back. And this mean machine will be waiting for him.1. Kawasaki is quickly becoming the big-power leader in motocross and off-road. To keep that reputation, the factory EnduroCross bikes feature a highly modified motor. The team guys would reveal nothing, but from snooping behind the semi and from our experience testing their bike last year we’re almost certain it’s a 280cc motor. Both Dietrich and Damon Huffman run a two-speed transmission, which consists of first and second gear. However, since the final-drive ratios vary from track to track so much, the similarities to your KX-F are nonexistent.2. This impressive skid plate is supplied by Kawasaki-sorry if you were looking for an early X-mas present-as of press time it’s not available for purchase. A full Hinson clutch treatment is tucked in behind that cover. Kawasaki has a bad taste in its mouth from an auto-clutch failure with Nathan Woods back in the day. The company has no interest in trying them again even though more than a majority of its competition is running some sort of auto-clutch system. CV4 high-temp hoses and Zip-Ty Racing’s magnetic oil filter cover round out the goodies.3. Dunlop’s GeoMax MX51 rear tire is used exclusively by the Kawi team. Their tire-grooving looks like it was done in-house at Dunlop, but it’s all EX Team work. Underneath, the team uses the Tire Balls system. Testing revealed Tire Balls allowed Kawasaki to get the low air-pressure characteristics it wants for maximum grip but still kept the tire on the rim without slipping.4. This is not a production Dunlop tire. It’s a hard-pack model only available for factory teams such as supercross and EnduroCross squads. Kawasaki’s front-tire theory is that hard-terrain tires are better since every obstacle is hard and there are plenty of obstacles out there.5. This Acerbis guard has obviously done its duty protecting the front brake rotor. This was shot before practice as the bike waited for Dietrich’s return.6. Footpeg location moved 10mm back on the factory Kawis. The team took a look at trials bike ergonomics and had IMS build this footpeg setup to get their riders more over the rear of the bike hoping to gain balance over the more technical sections of the track.7. This brake pedal-arm stop, inserted into the swingarm pivot recess in the frame, keeps the brake arm from being knocked up too high in the event of an impact from below. Keeping the pedal straight is one thing, but ensuring the brake’s plunger assembly doesn’t get dislocated from the master cylinder (total brake failure) is top priority.
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<p><strong>Zip-Ty Racing Husqvarna</strong><strong>Cory Graffunder #118 TC250</strong><br/><br />
Cory Graffunder has nailed two podiums in a row this year aboard his new Husky TC250. In fact, since joining the team after the first round he’s been nothing but impressive-aggressively battling the other factory boys and taking over the lead in the E3 Spark Plugs’ EnduroCross Pro Junior Championship chase. He’s also sitting third in points at the halfway point and his bike has a lot to do with that.1. Graffunder and teammate Gary Sutherlin both run identical Husqvarna TC250 motocross bikes. The motors are surprisingly stock with only the Jardine exhaust bolt-on and Ty Davis’ usual gamut of carburetor mods (which include dialing in the accelerator pump, fanatical jetting work and sleeving) and Zip-Ty Racing accessories. Both Husky riders were using full Rekluse Z-start Pro auto-clutches in their bikes. A late addition was an iCat in-line spark wire mod. This bike is making enough power to beat a big-bore KTM to the first turn, so that says something for a stock 250.2. This is how you build a bulletproof drive assembly. The longevity of the SuperSprox rear sprocket isn’t absolutely necessary in EX’s eight-lap main events, but rest assured it won’t be missing any teeth afterward. The T.M. Designworks chain guide is almost required.3. Jardine custom builds this overlay into its Zip-Ty Team-issued EnduroCross headers. Preparing for the inevitable rock, log and tractor tire is part of the game.4. The Zip-Ty Racing Husqvarna team has some sano grooving going on out back with these Pirellis. Up front, the team runs a hard-pack front without grooves. Notice the holeshot device. Every team runs some form of holeshot device. The tight start straights make it important to get out front.
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<p><strong>AM-PRO Yamaha</strong><strong>Jason Raines #100 and Kyle Redmond #14 WR250</strong><br/><br />
The Am-Pro Yamaha team is making its first go at a full season of EnduroCross. Usually taking on the multitude of Eastern U.S. off-road series, the Am-Pro guys are hitting every EnduroCross round and have built up their machines to make them competitive. Starting out as Yamaha WR250s, these bikes are some of the trickest around, but just like the Zip-Ty Husky team, there’s no reason you couldn’t build your own.1. Both Raines and Redmond run WR/YZ hybrid motors punched out to 290cc thanks to the Athena/GYTR kit. The top end features YZ cams inside the stock WR head. FMF takes care of the exhaust with a MegaBomb/4.1 system. The kickstarter is retained for backup and the WR E-start remains intact. Raines runs a full Rekluse clutch setup, while Redmond prefers the stock manual clutch.2. Kyle Redmond wants more airflow into the carb so his bike has these breather holes. Seems risky in the ponds of EnduroCross, but on the inside foam and wire mesh backing stop the splashes. Inside this airbox you’ll find some other mods. Am-Pro Yamaha removes the battery tray and top of the airbox and they mount the bike’s CDI unit inside. Where does the battery go? Under the motor inside the skid plate, of course! In our experience these are the lightest-feeling WRs in the sport-the weight redistribution of these parts plays a big role in that.3. A GYTR skid plate protects the motor and a relocated ultra-lightweight E-Batt Dry Cell rechargeable battery.4. Fastway Performance F3 pegs with spike inserts offer grip no matter what the EnduroCross course throws on them. And the GYTR brake clevis looks cool and tightens up the feel.5. Jason Raines is one of the only EnduroCross pros running a stabilizer. The GPR is mounted over the bar and helps Raines keep his bike’s ProTapers pointed in the right direction.6. This Zip-Ty Racing sharkfin rear disc guard can be seen on the majority of bikes in the EnduroCross pits. Raines’ guard isn’t new, but it’s in a lot better shape than others! What these bikes go through…7. Both Am-Pro Yamaha EnduroCross riders run Kenda Budds Creek Sticky front and rear tires. Redmond’s rear tire (shown) is grooved deep, while Raines isn’t sold on the technique and runs his tire stock out back. Both pilots use ungrooved front tires and well-worn foam inserts inside the front and rear for maximum flex.8. BulletProof Designs isn’t a sponsor. Jason Raines bought these guards because they looked almost indestructible. We’d agree.9. Folding lever technology isn’t new but its implementation in EnduroCross is smart. The Am-Pro team drops full-wrap guards for flag-style Cycras to avoid getting stuck in the full-wraps if/when someone goes over the bar.
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<p><strong>Christini All Wheel Drive</strong><strong>Geoff Aaron #4 KTM 300 XC</strong><br/><br />
Christini All Wheel Drive Motorcycles and Geoff Aaron have had a pretty good relationship. They’ve gone to Europe for Erzberg and Romaniacs, and the friendly 10-time AMA National Trials Champion always puts in a solid run and is one of the original EnduroCross racers. Some of Aaron’s impressive stats are starting on the second row at Erzberg and somehow finishing sixth and nailing down fifth at Romaniacs. That’s just gnarly. His podium appearance in South Carolina put him firmly into second place in the Geico Powersports AMA EnduroCross point standings and ready to pounce on anyone’s mistake. His bike mods are pretty simple-if you don’t count that All-Wheel-Drive thing.1. The biggest mod to Geoff Aaron’s ride is the Christini All Wheel Drive system. His bike is a nearly new KTM 300 XC that Steve Christini personally supplied. His motor is stock but uses an FMF pipe and Shorty silencer. Geoff’s big for a racer. He’s over 6 feet tall and more than 200 pounds but keeps the suspension stock (except for the Christini mods to the fork). When you watch him ride, you can see he uses a lot of motor control to get the bike to do what he wants and lets the soft action of the suspension cruise over the bumps. He’s got the smoothest riding style on the track and often comes from nowhere to the front. Even though the 300 is perfect for him, it hasn’t gotten him a start. That’s mostly due to the weight factor of Geoff and the Christini. Someone build him a small tank, already!2. This trick sharkfin rear disc guard is a Christini part. The tires are Dunlop GeoMax MX51 front and rear with heavy-duty tubes. Aaron runs as low as 8 psi in the rear at the beginning of an event and will even drop that pressure throughout practice and qualifiers to get the right feel.<strong>Lucas Oil Kawasaki</strong><strong>Colton Haaker #5 KX250F</strong><br/><br />
Colton Haaker represents the younger trials-crossover crowd in EnduroCross as well as the privateer lifestyle. His ride with Lucas Oil is pretty sweet in that it gets him to the races every week, but other than that, the youngster has a lot of work cut out for him every round. His bike has survived the first half of the EnduroCross season. This is how.1. Colton Haaker runs a stock KX250F motor. Other than a Yoshimura exhaust, it’s all stock. He’s experimented with the big-bore scene but thought the stock motor had plenty of grunt. He does rock the factory carbon fiber skid plate, though. Those cool CV4 hoses keep popping up on EX machinery. Tougher than stock is always a good move.2. The rugged life of EnduroCross is evident in the abuse the Yoshimura exhaust has taken aboard Haaker’s rides. This is after two races with a trials rider at the controls. It’s hard enough to have shiny new parts every week as a privateer in motocross. In EX, it’s impossible.3. BRP handles the chain guide duties aboard most Kawasakis. Here, you can see that’s not a very nice job. This lucky part doesn’t even have it that bad as Haaker generally cleans his obstacles with trials grace. The flexing welds on the swingarm are begging for reinforcement.4. Surprisingly, Colton Haaker is the only EnduroCross pro-class contender running the lightweight Nue Tech Tubliss system. He can drop to 8 psi in the front and rear “tubes” and be almost guaranteed to avoid failure. Haaker has some serious grooves cut into his Dunlop GeoMax MX51 rear tire as well.</div>

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