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

1989 TC 510 B two 'parallel' restorations

Discussion in 'Vintage Restoration Projects' started by daftmate, Jan 12, 2014.

  1. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Wow you did have fun didn't you, thanks for the pictures. Have my plan of attack sorted for the weekend.

    1. Turn up a mandrel on my ancient lathe.
    2. Drill a hole across the hollow dowel and put a small stiff bar through, extract the dowel.
    3. Been soaking the casing/inserts in penetraing oil most of the week.
    4. Put casing in the oven at 200 C.
    5. Push out the inserts using the mandrel on a hydraulic press.
    6. Measure up for new inserts and clean up the facing surface on the cases.
    7. Turn up on lathe.
    8. Press into place
    9. Take finished casings to the power coaters on the way to work Monday morning.

    Well that's the plan, will show you what actually happened when I get to step 9......

    Cheers
  2. Wildebeest90210 Husqvarna
    AA Class

    Location:
    Gloucestershire.
    Throw in a couple of beers somewhere and that sounds like a recipe for a great weekend !
  3. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Don't forget it's the first six nations game ! Could he a good (or very bad ) weekend. Vive La France, allez Husky....
  4. Michel Dufayard Husqvarna
    Pro Class

    Location:
    France
    Sorry !
    France 26: England 24
    Champagne !!! :banana:
  5. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Merde! So bloody close but what a great game. Wish I was at the Stade de France, but never mind out at my local pub 'The Peacock 'was pretty emotional.
  6. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Had a bad garage day as well. Followed plan religiously upto point 1. Managed to fill the big house up with oily smoke owing to repeated heating of crankcases. Wife very impressed. Inserts have moved a bit (like 2-3 mm ) but really stuck now. Got hollow dowel out, only highlight of day. Crankcase rear mount procedure was such a disaster, so went onto another easier job. Tried to removed seized mudguard mounting stud in bottom fork yoke. It snapped off, Crankcase rear mount mandrel.jpg Rear mount removal.jpg Tools for rear mount removal.jpg Hollw dowel removal.jpg went to pub to watch the rugby. We lost. Pictures attached, of the bike not the rugby. Have decided to take up knitting.

    Will try again tomorrow once the hangover has reduced to manageable proportions. Cheered myself up by bidding on yet another lost cause on ebay. Hope I don't win.

    DM
  7. SA63 Husqvarna
    AA Class

    Location:
    Glasshouse Qld, Australia
    Husqvarna Motorcycle:
    84 510, 500 auto , 86 510
    I get away with using the (outside) weber bbq with thermometer without too much whingeing from the better half, only snag is the brown patina on alloy from burning old fat.. and I can pull the bit concerned straight out onto the floor and start smashing (and swearing).
    I do like it though when you pop the lid , the smoke clears and the bearings have already fallen out!
  8. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Rear engine mounts saga ...... over and out. Had a vision delivered from the husky gods during a very disturbed nights sleep

    This is how I did it, no heat just careful use of the hacksaw. IMG_0334.JPG IMG_0337.JPG IMG_0338.JPG IMG_0340.JPG


    Feeling smug, so back to the pub men ! All we now is for France to loose their next game and us to beat the Welsh at Twickers and we get to win the six nations before taking world cup glory.

    DM
    firecrackerkid likes this.
  9. Wildebeest90210 Husqvarna
    AA Class

    Location:
    Gloucestershire.
  10. RUF Husqvarna
    AA Class

    Location:
    SACRAMENTO
    Husqvarna Motorcycle:
    510 air, 400WR 85, 430WR 87
    Other Motorcycles:
    BMW R80GS, GILERA 175RC 1972........
    SUPERJOB, Daftmate....:notworthy::notworthy:....
  11. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    OK back to more serious stuff, here's the strip report on the yellow framed bike (blue race No 5 on the first pics posted) that forms the other leg of this parallel resto. Both bikes are the same year and model, the white framed one is detailed above and was in a lot better nick than I suspected from outside. This one was a runner and looked to be the better one of the two. The bike has also been on Cafe Husky before when 'Cameron' owned it, and as I said before, very useful to look up the previous work done on it.

    Sure it was well meant but loved the rear exhaust mount, true dual purpose.
    P1000095.JPG

    Frame is needing some repairs, cracks on both bracing plates in same place either side of the headstock (just above the steering stop).
    P1010024.JPG

    Footrest mount tubes look to be bent backwards especially on one side. Sat it alongside the other frame for comparison.
    P1010098.JPG
    Theres no mount for the coil behind the headstock, found it bolted to the back of the airbox.
    P1010093.JPG
    Rest of the bike came apart pretty easy. There is a small crack on the swingarm around the linkage brackets, nothing like as bad as the first bike and not previously repaired. Should be easy to weld up.

    Think the biggest issue with the frame is whether to straighten the footrests or not. Will struggle to leave as is, nothing looks worse than droopy footrests, feels bad to ride on as well. Will probably give one of the frame people a call for advice on this one. Have bid on a cheap replacement frame on ebay just in case.

    Forks and white power shock has gone off to same place as bike 1 (Reactive suspension). Will put engine strip in next post so I can include pics.
  12. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Engine strip, didn't screw up this time and all came apart without damaging anything. Just as well because it has managed to do more than enough of that on its own without any help from me. Noted some differences from first engine:

    Roller brearing on gearbox output sthaft, different clutch securing system with half moon washers and clamp nut rather than bush and circlip.

    P1010044.JPG

    This is how I extracted the primary drive and cam chain sprocket, not elegant but only cost me a tenner for the three leg puller. Jubilee clip round the legs helped a lot and this time protected the shaft end by screwing the nut back on the shaft and putting a socket over the top.
    P1010055.JPG

    The connecting rod has been replaced but there was a lot of wear in the small end, the gudgeon pin was about four thou down in the wear zone and it was very loose in the piston. Big end feel fine and mains are new. Once the casing were split though found two of the dogs were missing from one of the gears (think it's third). Looking for new pair of gears.

    P1010074.JPG

    So crank and barrel have gone off to Motosupplies, as per bike 1. Hoping I will not need a new rod on this one, but think piston is due for replacement. Interesting to compare the two casings and internals, cranks are different. Later one is completly circular, early one has cut outs by the big end. One engine has a seal retainer on the drive side crank seal.

    P1010107.JPG

    Quite good fun doing two at once, apart from really having to store the parts carefully so they don't get mixed up and the potential amounts of cash all this is going to take.

    Also just bought another 1999 TC on ebay.......she did'nt take it too badly really.

    DM
  13. suprize Husqvarna
    Pro Class

    Location:
    Bendigo, Australia
    Husqvarna Motorcycle:
    WR 400, bike in a box Moto Villa 350
    Other Motorcycles:
    ktm 300
    we have just sent the pommie cricket team home...... they need a teardown and rebuild also:lol:
  14. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Last weeks ebay biddding has borne fruit, gentlemen here is H4. A 2000 410 TE with a bit of bling and de-enduroed .... also proof that Husqvarna does fit inside BMW (sorry that was last weeks corporate structure). I'll put this one in a different thread in the single cammers sections. Quite like the black livery and monster graphics.

    Regardiing progress on the 89's I have received a call from Motosupplies who are doing the important engine bits, will post the outcome later in the week after I've paid them a visit . In the meantime here's the pics of H4 (simply means my 4th husky). I picked it up a long way from home hence the use of the beemer rather than the usual motobanger and trailer . IMG_0342.JPG IMG_0351.JPG IMG_0350.JPG IMG_0352.JPG

    DM
  15. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Engine strip update.

    So all the critical engine components have been away to the specialists. Fully stripped and repair budget asssesment made. Motosupplies made a nice job but have decided to take all the stripped parts back just to have a better feel for the options. Cost for the strip clean and inspect was very reasonable, so thanks Paul for your patience I'm sure I'll be back pretty soon.

    What made me think again was that I was probably going to end up paying around £1200-1500 for both engines to do 100% job. Plating both cylinders, replacing all valves/pistons and new rod and big end on the early engine. I just picked up a really nice 2000 TE 410 for £620 complete so that made me rethink what I was doing. I can use that engine/bike to get me on the track this summer whilst I sort out the original engines at a slower pace. Besides looks like the suspension overhauls are also going to be very expensive, more on that next time.

    Here's the pictures of the stripped engine components, might be useful pics for other cafe husky rebuilders.

    IMG_0385.JPG IMG_0386.JPG IMG_0381.JPG IMG_0382.JPG

    Started sourcing some parts, HM racing in UK had valves listed at a very reasonable £25 each, anyone used them ?

    Next task on the engines is to get all the casing cleaned and powder coated, can drop them off when I pick up the newly coated frame on the 2000 TE 410. Sorry couln't help myself whilst it was all stripped......

    Any sources for cheap engine bits for 89's pls let me know. Have picked up a spare set of 5 speed gears and crankcases (just in case) oh and a swingarm and frame. Well you just never know do you, will be real good at swopping husky bits between years/models by the time I've finished these.

    DM

    PS Rugby update for my French friends on here: England playing Ireland today, and could go top of the table. So sorry to see the French mess up against the Welsh last night.
  16. Michel Dufayard Husqvarna
    Pro Class

    Location:
    France
    Rugby: When you are bad, you loose ! France is on or off.
    Pole vault : Have you seen the pole vault world record by Renaud Lavillenie ?
  17. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Rugby: guess we won then. Just got mail from reactive suspension both shocks (the Ohilins and WP) are basically u/s, back to the drawing board then. Anybody got any bright ideas how to get these bikes mobile without re-mortgaging the house (again). Guess a later shock plus overhaul maybe cheaper than just going the new replacement route. What later ones still fit the '89 ?

    DM
  18. SA63 Husqvarna
    AA Class

    Location:
    Glasshouse Qld, Australia
    Husqvarna Motorcycle:
    84 510, 500 auto , 86 510
    Whats wrong with the shock? Normally you can adapt a seal head to fit, just need to match the shaft size??
    We have a guy hear in Brisbane who will do any shock for $150 - 175 A$ . puts his own seal heads in I think.
    Shaft hard chrome I+ grind s around $80-100 I think
  19. troy deck Husqvarna
    Pro Class

    Location:
    Republic MO
    Husqvarna Motorcycle:
    87 250wr 12 cr125
    Other Motorcycles:
    kx65 ty80 rm80 kdx250
    u/s= unserviceable ?? thats almost impossible but it mite be cheaper to find a replacement :cry:
  20. daftmate Husqvarna
    AA Class

    Husqvarna Motorcycle:
    2 x '89 TC510, 1x '89 TE510 +7 more.
    Other Motorcycles:
    BSA 10, Matchless G3LS, Yamaha HL540
    Probably wrong to have said u/s for the Ohlins but the WP seems to be. I hope Gareth (runs reactive suspension) is OK with me posting copies of our correspondence but intend to visit then later this week and make sure its OK. Anyway part of posting all this stuff is to give cafe husky members a typical idea of the costs and rebuild decisons. So here you go, any advice/alternate approach appreciated. I do think spending decnt money is really worthwhile as its make such a difference. Getting the spring rates right on both ends will the starting point. So here goes, like all mail trails start at the bottom and work your way up.


    Hi
    I’ve had a look at your shocks. I’d severely underestimated just how bad the corrosion was. To get the two Ohlins shocks back to how they should be, you’d be looking at around £550 each.

    I’ve got one virtually stripped but there are some parts that have welded themselves together so I had to take it apart a different way. There may be more parts to add to the list but I’d have to take a hacksaw to the body to see if I can rescue them first. The other Ohlins is corroded in the same way so I’m guessing that it will need the same parts.

    I played with the WP for ten minutes then abandoned it, I think that one can be written off.
    Gareth.
    Sent: Wednesday, February 19, 2014 1:17 PM
    To: Reactive Suspension
    Subject: RE: forks and shocks

    Many Thanks Gareth for the report,

    My initial thoughts are :

    1. FORKS - WP 4054 forks . I’m not a light guy, currently around 17 st kitted. I don’t ride that hard anymore but like the front end to sit up, these early huskies were hopeless at holding tight lines so always looked for the outside berm to bounce off to get the damn thing turning. Could maybe live therefore with the existing springs provided they are slightly stiffer than standard not weaker.

    Money wise is about what I expected but like everyone have to watch the budget a bit ……and have thought of the following:

    1.1 How much is a new set of 4054 ? you mention it on your website.
    1.2 May do one set of WP forks only as an ‘original’ ’89 show queen ridden on some Sundays….so could compromise on the ultimate performance provided they cosmetically look the dogs. How much extra would be the fancy gold coating on the stantions that looks great.
    1.3 The second bike will be the ‘racer’, not too bothered about originality and will be upgrading some critical bits. Have just bought a complete 2000 husky cheap off ebay with 45 mm USD Marchochi’s they look good nick and would bolt straight on with yokes. Would ask you to give them a service, assuming no major damage how much roughly would that be ?
    2. SHOCKS go ahead with the Ohlins, the WP sounds a real pain. Any way to fix up the spare ohlins with the busted bottom mount ? Also love the look of your fancy spring thrust washer to assist spring adjustment so please include those. Guess you will not know the WP repair costs but a days labour is not a good start just for stripping. May be more economic for me to source a serviceable second hand unit ? Ohlins or WP or….appreciate your guidance.

    3. I’ll need to bring in the forks and shock (sachs) from my latest purchase for servicing at least. Any day better for you ? we can discuss the above at the same time.

    Cheers




    From: Reactive Suspension [mailto:info@reactivesuspension.com]
    Sent: 19 February 2014 09:45
    To:
    Subject: Re:forks and shocks


    Hi

    I’ve stripped the forks, but not tackled the shocks yet. I’ve learned from previous experience that when your stripping old WP shocks you have to set a day aside to do them, unfortunately I’ve not had the time to do that yet.

    Looking at the forks, they will need re-chroming, new bushes and seals and some small internal parts. The springs that are in there are stiffer than anything that’s currently available off the shelf. Custom springs could be made if necessary.
    As a very rough estimate I would say that to sort the forks out you’d be looking in excess of £800, depending upon how much the internal parts may be, I’m still trying to track down some bits.

    Looking at the Ohlins shock I’d say you would be looking at a cost of around £225, to re-plate the body, powder coat the spring and replace the usual service parts, until I get it apart it’s difficult to be more specific than that.
    The WP shock I have to get apart first.

    All the best,
    Gareth.