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

1987 WR250 Husqvarna Rescue Rebuild

Discussion in 'Vintage Restoration Projects' started by jonhicks, Jan 13, 2017.

  1. jonhicks Husqvarna
    AA Class

    Husqvarna Motorcycle:
    1987 250 WRLC
    Other Motorcycles:
    IT175J 1982 YAMAHA
    Hi there everyone,

    This thread will cover the rescue/rebuild of my "last of the Swedish" 1987 WR250

    Below are the photos of the eBay listing when I purchased the bike from Brisbane Australia in March 2015. Lot's of new parts were included in the purchase as you can see form the photos.

    The engine require a complete rebuild:
    • Every seal
    • Every bearing
    • Rebore
    • NOS Mahle piston
    • New Clutch
    • New radiators (Chinese replicas not the best fit)
    • New radiator hoses
    Other works also carried out:
    • Front wheel spacer to get the WP forks working correctly with the Nordisk KTM rim (san blasted orange hub)
    • Sandblasted the rear rim as it was painted black
    • Ohlins shock rebuilt new bump stop fitted
    • Shock linkage bearings replaced
    • Swing arm bearings replaced
    • New front brake line
    • New front brake pads
    • New UFO Rear light assembly Cassons (Aust Distributor) Part No 1307
    The list goes on - I'll upload more images of the work carried out throughout the rebuild and assembly
    It's been a decent challenge and learning curve getting this box of part ands bolts back together as a running bike again - but lots of fun. Cafe Husky has been an amazing resource thanks for the content you guys make available - the information & photos have been price less.
    $_57 (2).jpg $_57 (3).jpg $_57 (4).jpg $_57.jpg
    justintendo, Eurofreak and 2premo like this.
  2. jonhicks Husqvarna
    AA Class

    Husqvarna Motorcycle:
    1987 250 WRLC
    Other Motorcycles:
    IT175J 1982 YAMAHA
    After having the bike collected it was placed into storage - a few more images for reference of what parts had been included with the purchase
    IMG_0574.jpg IMG_0571.jpg
    IMG_0566.jpg IMG_0564.jpg
    Ricky husky, justintendo and 2premo like this.
  3. jonhicks Husqvarna
    AA Class

    Husqvarna Motorcycle:
    1987 250 WRLC
    Other Motorcycles:
    IT175J 1982 YAMAHA
    Some of the new parts that were included

    Full complement of seals & braided throttle & clutch cable
    IMG_0579.jpg

    Boyesen Reeds - these were tricky to fit - had the leave the plate of where the screws go in and it would seat into the inlet on the barrel it was hitting on the reed screw heads it that makes sense? So had to install without the backing plate - not super comfortable with this as I question whether it will put strain on the reeds.
    IMG_0580.jpg

    New UNI Airfilter & UHD tubes
    IMG_0581.jpg IMG_0582.jpg
    justintendo and 2premo like this.
  4. jonhicks Husqvarna
    AA Class

    Husqvarna Motorcycle:
    1987 250 WRLC
    Other Motorcycles:
    IT175J 1982 YAMAHA
    Some of the chassis and frame parts - the side covers are in reasonable condition with good yellow backgrounds
    IMG_0750.jpg IMG_0751.jpg IMG_0752.jpg IMG_0753.jpg
    justintendo and 2premo like this.
  5. jonhicks Husqvarna
    AA Class

    Husqvarna Motorcycle:
    1987 250 WRLC
    Other Motorcycles:
    IT175J 1982 YAMAHA
    The engine rebuild -

    Upon inspection the existing piston was in poor condition as was the head and barrel
    IMG_5843.jpg IMG_5847.jpg IMG_5848.jpg IMG_5845.jpg
    justintendo and 2premo like this.
  6. jonhicks Husqvarna
    AA Class

    Husqvarna Motorcycle:
    1987 250 WRLC
    Other Motorcycles:
    IT175J 1982 YAMAHA
    Next was determining the exact state of the barrel and piston and work out which replacement piston could be used.

    This was quiet tough to workout given its a non power valve version with 66mm bore - from what I've read there is only to oversizes for this model -
    Part number 16 16 387-03 / 161638703 was ordered from Italy along with matching rings 66.94MM not sure what I can do next once that piston wears out - I've read mixed thoughts on which piston would work as a replacement - it has a longer skirt on on the exhaust manifold side.


    Does anyone know of another piston I can use to go up another size? - it would be helpful given there was some slight marking in the barrel that honing did not clear up




    IMG_5841.jpg IMG_5851.jpg IMG_5850.jpg IMG_5879.jpg
    justintendo and 2premo like this.
  7. 2premo Husqvarna
    Pro Class

    Location:
    Northern NV
    Husqvarna Motorcycle:
    98 WR360, 1987 WR430, 1988 XC430
    Other Motorcycles:
    Sherco 300, 2002 KTM 380EXC
    good find with all the really great NOS and new parts
    look forward to watching your progress
    good base of quality parts
  8. wrx Husqvarna
    Pro Class

    Location:
    845 newyork
    Husqvarna Motorcycle:
    1973 to 1986 husky's various models
    Other Motorcycles:
    RM -250 / Buell / Penton 400 mc5
    please dont put that yamaha front fender on it. Acerbis NOST is still available and is what they came with fron the factory. just my 2 cents. good luck with it. shoulg be a fun build.
    justintendo likes this.
  9. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    please dont put that yamaha front fender on it. I couldn't agree more, nice build so far
  10. Eurofreak Husqvarna
    AA Class

    Location:
    Western NY
    Husqvarna Motorcycle:
    1986 TE 510, 1982 CR250, 2008 WR250
    Other Motorcycles:
    70's Triumph , Bultaco , Maico, etc
    When the cylinder is too worn it can be Nikasiled and sized to a piston you provide. The bore will last a lot longer too.
  11. justintendo klotz super techniplate junkie

    Location:
    mercer, pa/northwest pa
    Husqvarna Motorcycle:
    84 250,86 400,87 430,88 250,95 360
    Other Motorcycles:
    99 kawasaki zrx 1100
    nice score! my favorite of the swedes...keep us posted with more pics!
    87husky500xc likes this.
  12. oldbikedude Husqvarna
    Pro Class

    Location:
    Honey Brook Pa.
    Husqvarna Motorcycle:
    1988 wr 430 with cr suspension
    Other Motorcycles:
    66flh,67 CA77,76 CR125M,73H1,74ty250
    I saw that for sale. Congrats on scoring it. Lots of good parts there. You still will have a lot of work on your hands. I am looking forward in watching your build. Keep the great picks coming...your gonna love that bike when it's done.
  13. wrx Husqvarna
    Pro Class

    Location:
    845 newyork
    Husqvarna Motorcycle:
    1973 to 1986 husky's various models
    Other Motorcycles:
    RM -250 / Buell / Penton 400 mc5
    you really should have that backing plate for the reed petals installed. maybe double or triple up on the gasket that goes in between the cage and the cylinder.
  14. Eurofreak Husqvarna
    AA Class

    Location:
    Western NY
    Husqvarna Motorcycle:
    1986 TE 510, 1982 CR250, 2008 WR250
    Other Motorcycles:
    70's Triumph , Bultaco , Maico, etc
    Looks like a great project. Can't wait to see how it comes out.
  15. Joedints Husqvarna
    AA Class

    Location:
    Medford, New Jersey
    Husqvarna Motorcycle:
    11 WR300 13 WR125 81 WR430 82 CR250
    Other Motorcycles:
    Kawasaki ZR7-S
    I had that same bike, purchased new from the dealer
    justintendo likes this.
  16. jimspac Husqvarna
    Pro Class

    Location:
    Connecticut
    Husqvarna Motorcycle:
    82 250WR, 82 430WR, 84 250WR, 85 400
    Other Motorcycles:
    86 400WR, 82 Montesa Cota 349
    The pocking in the combustion dome of the head and the top dome is showing indication of the engine running with a disintegrating big end bearing. Do check the rod by trying to pull it up and down without the crank rotating and feel for radial play.

    I have seen the same in 2 out of six Husqvarnas I currently own. Both engines looking like that required a rod kit installed or replacement crank. I have done both thus far
    justintendo likes this.
  17. ajcmbrown Husqvarna
    Pro Class

    Location:
    Metung Victoria Australia
    Husqvarna Motorcycle:
    400WR 250WR 07 WR500 430AE 360AE
    Other Motorcycles:
    1985 500CR Ducati Multistrada 1200S
    Jon it appears that you have the wrong model caliper, unless you have the original?
    Your bike should have the dual piston Brembo caliper but the one pictured looks like it's from a 1986 model.
    Tony.
  18. 87husky500xc Husqvarna
    Pro Class

    Location:
    Dayton NV
    Husqvarna Motorcycle:
    2020 tx300i and a few vintage bikes
    Other Motorcycles:
    77 honda xr-75..
    Well put and I definitely second that. Just a great all around bike. I'm faster on my 87 250 wr than I am on my 15 te300 in the right stuff it just doesn't get as much seat time cause parts can take a lot longer to source out.
  19. justintendo klotz super techniplate junkie

    Location:
    mercer, pa/northwest pa
    Husqvarna Motorcycle:
    84 250,86 400,87 430,88 250,95 360
    Other Motorcycles:
    99 kawasaki zrx 1100
    dont tell me that! ill never buy a new bike haha...
  20. 87husky500xc Husqvarna
    Pro Class

    Location:
    Dayton NV
    Husqvarna Motorcycle:
    2020 tx300i and a few vintage bikes
    Other Motorcycles:
    77 honda xr-75..
    Dont get me wrong, the te300 is an effin animal! Absolutely incredible bike. The 87 250 is just damn near perfect with minimal effort. That as well as having a lower seat height than the te and I don't quite have the suspension dialed like I do on the 87. I've also had the 87 for years and years so once I've had the 15 that long I'm sure it'll be perfect too haha
    justintendo and 86 400 XC like this.