1985 500CR

Recently I picked up a rather unloved Husqvarna advertised as "83/84 wr240 rolling frame with plastics & blown wr 500 motor" which was referred to me by another Aussie Husky rider.

It was immediately obvious that the seller didn't know what he had and for $500 and a six hour return drive it was back in my workshop.

I knew it was ugly, but even I was a bit shocked!




I initially thought it was a 500XC but thanks to 86 400 XC's excellent FB page it was pointed out that I have a 1985 500CR with Australian compliance plates from a 240WR, I assume partly because a 500CR couldn't be registered in my state of New South Wales, and also because registration is dirt cheap on motorcycles under 300cc.

So once I got it home it was time for the strip down, boy was I in for a surprise!

It appears as though one of the pressure plate bolts (there's a story in those too) had come loose and machined a disc out of the clutch cover, then it was welded back in, of course it's a mess.

I also knew that the rhr cylinder stud area of the cases had been "welded" up for some reason and also the area where the steel sleeves fit into the rear of the cases had been attacked by the welder too.

The left side case didn't go without some modification either, the boss which the holds clutch cable has been ground off and then an elaborate bracket was made which worked its way from the front engine mount to behind the cylinder.

These cases are junk, but I have a set being repaired from my original 1988 400WR.

So engine out, it turns over quite well but there were more surprises hiding in there too.

It appears to have had a new Wossner piston not too long ago, but then it had been siezed lightly, but also felt sloppy in the bore.

The big end has some vertical movement, so that will need rebuilding.......

Off with the clutch cover and I find myself looking at four different types of bolts holding the clutch pressure plate in place.

The centre clutch hub needs to be replaced too.

About the only bullet I have dodged so far is the kick start idler bear bearing, as I took it out, the rollers began to fall into my hand.

I had quietly hoped that the transmission would be in good/usable condition, wrong! The gear teeth are very worn and the engagement dogs are very rounded. It is a six speed transmission which I thought a bit odd in a CR engine.

One more piece of good news is that the cylinder was measured at 87.49mm through the entire stroke, so another 87.42mm piston will be ordered.

Tony.

After a good look at the frame, it is actually quite good, it needs a couple of minor weld repairs which I can carry out.

The Ohlins shock came apart nicely and appears that a new set of seals, oil and a spring repaint will have it back in service.

The fork chrome looks good, I haven't checked them for bends yet.

A little more good news, I found a 400WR bottom end sort of locally, but I'll need to change the rear steel bushes since it's from 1984 twin shock bike.
It doesn't have a clutch and the cases look good, I won't know the condition of the transmission until I split the cases though.

Now the hunt begins for parts needed, I have sourced an airbox, but still need the airbox cover and the right hand rear sideplate, rear guard, I have a new Acerbis front guard, seat cover, decals, front number plate, piston kit, conrod, engine bearings and a brake hose.
I'm sure this list will grow as time goes on but it's a start.

Included with the bike was a very nice aluminium clutch cover, full engine gasket set and seal set which appear to be good quality.

Tony.

I love the truck! what is it? Nice, won't need a lower gasket just finish the weld around. That sprocket !! Hahahha. At least now she is in a good home!

Looking at that sprocket gives you an idea of the maintenance regime this bike was subjected to!

Luckily the weld doesn't matter any more, but I've never seen anything quite like that before.

The truck is a Ford Falcon FG-X XR6 Turbo, fun drive! Sadly they are no longer produced.

A few more pics of how not to maintain a motorcycle.....

A very worn Mikuni slide, says a lot about filter maintenance!


This may provide some answers...


Obviously the PO couldn't afford a flywheel puller.


I assume the po thought it was a right hand thread, just look at that metal coming from the main bearing...

This is a nightmare and not many would save it.
All the nice parts on ebay that most likely came from much better bikes out there and this 1 gets a resurrection. Way to go Tony!

3 months till you ride it?

Honestly Steve if I had any idea of the level of ham fisted work, and it wasn't so far away, I may have just left it where it was.
I hope to have the replacement bottom end in the next week or so, the frame will go to the powder-coaters in the next couple of weeks, piston ordered, I just need to keep a bit of a lid on expenses but I feel that this will be worthwhile in the end.
It may not be 3 months, but it shouldn't be too long. The plastics and decals will chew up some $$$ I'm sure.

These types of bikes are the reason some builds take years. Motivation is the word, discipline is the key- I am the Infantry Follow Me!

It's in good hands now. Looking forward to seeing your progress.

There wouldn't be too many of us who would pass up a 500 Husky for $500.

You are of course 100% correct Slosh!

That slider looks like a tire tread. Nice! And the sprocket looks like a cam!

It was what appeared to be a bicycle tyre, I'm only guessing due to the bumps on the sprocket, there were no wheelies in its most recent rides!

I think his cousin sold me the 500 I have! hahahaha!

I found a carb slide resembling that in my 84 250WR when I tore it down. I found a few things in that engine run to the ragged edge.

I think the PO ran this right to the edge of going bang in a big way jimspac!

Everything in this pic is just plain wrong, retread rear tyre, sprocket with no teeth and flat head bolts instead of countersunk. The surprises keep on coming!
On a lighter note, my piston has arrived and as measured earlier, it fits the jug nicely.
Crank next, swap cases and transmission and I almost have this engine beat!
Frame welded and is currently at the powdercoaters, looking forward to getting it back home.
The rear shock is progressing nicely too, I found one pit in the shaft so I now have another shaft on its way along with a nice airbox cover.
Progress has been slow but things are beginning to come together.

That will be a nice bike when you're finished. Good luck with the restoration.