1. Husqvarna Motorcycles Made In Sweden - About 1988 and older

1986 Husky 510 4-stroke project bike

Discussion in 'Vintage Restoration Projects' started by ruwfo, Dec 29, 2009.

  1. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    Guys,
    Ok, my 1986 Husky 510 4-stroke project is finally moving forward, this is the most involved project i've every taken on. See i bought this bike as $100 parts bike? in 08/08 not sure if i saw thru all the work it needed, or because i've never seen one before. Well, with a motor that had spark my project began.
    Over the past year ,i found the 2 missing side cover /number plates,& air box assy, replacement front brake master cylinder, fenders & seat - to go with motor with less compression then a 125 2 stroke.

    As i know nothing about 4 strokes i dropped it off at a friend's shop, in 6/09 with the knowledge that when he got some time he'd pull it apart. I already know it would need piston & rings/bore job, but never knew stock valves were so expensive.

    Luck was on my side,the piston was a original bore, but the valves where burnt badly. It came down to, all new lower end bearings (for extra insurance as i planned on racing this bike), new Wiseco piston, valves, guides, valve seat grinding & complete gasket set. I'm still amazed that Halls Husky had most parts in stock, & i was able to get a new first over Piston on Ebay. In went Kibblewhite black diamondback valves instead of Husky ones, because the original were $450 vs $150.

    With motor projects, it's usually better to, not be cheap, if your planning on keep whatever it is your fixing, at least that's what i tried to tell myself. As this project keep getting pushed back on the funding/priority list,6 month later, the motor rebuild is at last finished .

    Attached Files:

    benny likes this.
  2. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    Can you polish a turd?

    Here's a few pictures of a afternoon of cleaning, & then later with few Husky items from Ebay (air box etc.)

    John

    Attached Files:

  3. schimmelaw Husqvarna
    AA Class

    Location:
    Rowlett, Texas
    John,
    Seems as though you can!! 2 builds at the same time - the 500 and this? I applaud your efforts and fortitude. Nice 4 stroke. Nice rebuild.
  4. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    They don't call me Husky John for nothing

    Rick,
    Yeah, thanks for the words of encouragement , technically i'm doing 3 restorations at the same time a 73 125WR too, lucky that ones my buddy's and he's paying for his.

    My good friend Paul at "Whoop de doo cycle" in NJ, loves vintage MX & he's been doing all my motor work. I consider myself extremely lucky to have his shop were i can work on my bikes & he doesn't mind have a bunch of old Husky s in pieces all over.

    This 510 rebuild has been a tough one, both in time & getting parts, it's had more starts and stops then a NYC taxi.

    But that's why they don't call me Husky John for nothing :D.
  5. Hwy Mini-Sponsor

    Location:
    SF Bay Area
    Husqvarna Motorcycle:
    '86 510TX / '90 250WXE / '87 510TE
    Other Motorcycles:
    '04 KTM 525MXC / '91 KTM 300DXC
    I agree on the parts. Being only a '86 you would think that parts would be more accessible, but that's not the case.
    I spent more time finding pieces for my build than the actually build itself.
  6. schimmelaw Husqvarna
    AA Class

    Location:
    Rowlett, Texas
    From now on you are "Husky John"! Never again will I address you as "ruwfo" or "John" - from now on you will forever be Husky John. (Maybe (rarely, if ever) "HJ" (capitalized, of course!) for short.

    Paul deserves lunch once a week too!
  7. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    86 decomp cable?

    Art,
    Where did you find a decompression cable ? Mine broke today-right
    at the lever?

    Husky John
  8. Hwy Mini-Sponsor

    Location:
    SF Bay Area
    Husqvarna Motorcycle:
    '86 510TX / '90 250WXE / '87 510TE
    Other Motorcycles:
    '04 KTM 525MXC / '91 KTM 300DXC
    I had Phillip at husqvarna-parts.com make me one in stainless. He can also do black covering. Send him your cable for reproduction.
    Motion Pro or Spiegler Performance Parts can also make one. Spiegler is the quickest in producing them. All about the same price at $60 more or less.
    http://www.spieglerusa.com/
    http://www.motionpro.com/ ask for Larry.

    Mine is shown in the middle of photo.
    Art

    Attached Files:

  9. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    The story/build continues- Twin shock racer?

    Art,
    Thanks :thumbsup: i'll look into those for my decomp cable.


    Guys,
    Well the story continues, in August 09 as we had close to all the motor parts , i started tossing around the idea of making a twin shock version drum brake racer out of it using a 1981 250CR rolling chassis, i found for a $100.

    In November i test fitted the almost complete motor in this chassis, & it fits, with only some minor frame mods needed to clear the carb better & leaving room for a pod filter or some type of airbox & some new motor mount plates.

    Note you'll need either an aftermarket exhaust or head pipes from the older (83-85) twin shock models also, but the pipes do clear the front frame.

    Attached Files:

  10. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    finished motor finally, & back in

    Ok, motor is done, never hear this one run so before so before i go too crazy with the twin shock frame version back in the stock frame it goes.

    Got to make sure every thing works the way it should before i tackle frame modifications & air box fab,etc.

    Not the prettiest looking bike,but considering what i started with i can't
    complain.

    Husky John

    Attached Files:

  11. Hwy Mini-Sponsor

    Location:
    SF Bay Area
    Husqvarna Motorcycle:
    '86 510TX / '90 250WXE / '87 510TE
    Other Motorcycles:
    '04 KTM 525MXC / '91 KTM 300DXC
    World's of difference than what you started with. Great start.
  12. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    It's alive

    Guys,
    Got my 510 start & rode it up & down the street last night:applause:

    Also damn near killed myself as the tires only had 4psi in them,my
    back brake was so out of adjustment it didn't work & the front
    disc is too powerful. Kicked it a few times,sounded like it waited
    to start so i jumped it, fired right up, up the street i go. Go to
    turn around & find no back brake & road salt all over the place,
    grap the front brake & almost go on my head :eek: LOL.

    Rode it back to the garage & out came the tools , now i've finally
    seen the light at the end of the tunnel (hope it's not a Train ;))

    Now start the cosmetic clean up, my favorite part of bike rebuilds,
    as you see the most difference.

    And of course I called Paul (friend/mechanic) 1st thing ,to tell him the great news
    I owe him lunch on Sat.
    later
    Husky John

    Attached Files:

  13. Michel Dufayard Husqvarna
    Pro Class

    Location:
    France
    Hello Ruwfo
    Do you still use a mikuni ( 38-40 ???)on your 510 motor ?
    If so, what are the jet tunings ?
    Thanks
    Michel
  14. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    Used a Dellorto

    Michel,
    Not i couldn't get the bike start with the Mikuni carb that was on the
    bike when i got it. Bought a used Dellorto 40mm off Ebay & that
    seem to do the trick :thumbsup:.

    This carb has 170 main, 52 pilot, 60 starter, 50 slide, k32 jet needle,
    & AB265 needle jet
    Husky John
  15. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    1 step closer

    Guys,
    Ok, 1 step closer to finishing , refinished gas tank with graphics
    from HWY (thanks Art), new seat cover, more cleaning & polishing,
    replaced sagging rear shock with another.

    Now some fine tuning, fork rebuilding & finally some riding of this
    near 2 year project, i'm pleased with how it's coming out.
    Considering the trud i started with :eek:.

    I'll post step 2 which will be the building of the twin shock Vintage
    racer, later this season.

    Husky John

    Attached Files:

  16. Husky37 Husqvarna
    AA Class

    Location:
    UK
    Husqvarna Motorcycle:
    84 CR500, 85 CR500, 89 TE 610
    2 Years.... and there's me being impatient at 5 months!!

    Nice job. Would like to know how it rides as I have never ridden a 4 stroker unless you count the BSA C15 back in.... :)

    Stu
  17. Leftcoast leftkicker Husqvarna
    AA Class

    Location:
    encinitas ca
    George Erl at Up Tite swears by the Dellorto (even over a modern Kehein!)
  18. Motosportz CH Sponsor

    Location:
    Vancouver WA
    Husqvarna Motorcycle:
    2021 TE250i, 570 Berg, 500 KTM, 790R
    Other Motorcycles:
    many
    Looks GREAT :thumbsup: Nice work.

    The vintage forum here on CH is really cool. Love the vintage pix and builds. Keep them coming :thumbsup:
  19. husqyhamm Husqvarna
    AA Class

    Location:
    South Africa
    Husqvarna Motorcycle:
    Quite a few 83-86 500 2Ts and 4Ts
    Other Motorcycles:
    84 R80 GS Dakar; Victory 106.
    Heres my 86TX being raced in our national VMX series.
    [IMG]
  20. husqyhamm Husqvarna
    AA Class

    Location:
    South Africa
    Husqvarna Motorcycle:
    Quite a few 83-86 500 2Ts and 4Ts
    Other Motorcycles:
    84 R80 GS Dakar; Victory 106.
    [IMG]

    Currently building two twinshock 4Ts. 83TX and 84TE, and 84 WR500. Will start post soon. Enjoy ur ride.