1987 500XC Rebuild

['87 500XC]

A while back I was going to turn this into a supermoto bike but that project fell to the way side. I am now going through the entire bike and replacing all that needs to be replaced. Started the project earlier this week.

Here's an overview of the bike.

My fathers old race bike.

Swapped front end to Gold WP 40/54 upsidedown forks Re-valved by moose racing to Husky team specs

Ohlins rear shock Re-valved by moose racing

44mm Mikuni carb jetted for 110 octane race gas

Carbon Fiber Boyesen power reeds

Custom clutch linkage with teflon cables for easy pull

Motor build by up-tite Husky November of 1991:
Extrude honed
Port timing changed
Custom expansion chamber
Increased compression ratio
Max oversize
250WR cases with webing machined out to fit the crank
6 speed gearbox
84+ HP

So far the project is moving along nicely, found a broken motor mount bolt which I already replaced and a cracked swing arm which I will V out and Tig weld. Other than that it's all wear and tear items such as chain and sprockets, brakes, tires, etc etc. Ordered parts from husqvarna-parts.com so hopefully I will see those soon.

Will keep you posted on project.

 

[colemanapp]

That is awesome and what a cool history. Arm jerker for sure.

 

[1Tuff500XC]

Wow, fantastic in the family history, and love the engine build details. Sounds like when I get to my 500XC project, I need to contact up-tite.

Looks awesome! Love the graphics.

Look forward to updates. Would love to see/hear a clip of it, once she's all freshened back up.

 

[1Tuff500XC]

That is one interesting lookin pipe to, and water pump guard.

 

['87 500XC]

That is awesome and what a cool history. Arm jerker for sure.

Yea, I can't wait to ride it. He says it's more linear like a four stroke but just never stops pulling. It'll be interesting haha.

 

['87 500XC]

Wow, fantastic in the family history, and love the engine build details. Sounds like when I get to my 500XC project, I need to contact up-tite.

Looks awesome! Love the graphics.

Look forward to updates. Would love to see/hear a clip of it, once she's all freshened back up.

The history is awesome. It was raced in double A class motocross and double A class harescrambles.

The graphics are awesome, unique and I havn't seen another husky from this year that looks like it. Most have yellow on the side panels.

 

['87 500XC]

That is one interesting lookin pipe to, and water pump guard.

Pipe was custom built by up-tite husky. They have a badge welded to the pipe but there name is barely visible anymore.

Water pump guard was custom made by my father. He got tired of breaking them haha.

 

[1Tuff500XC]

Can't wait to see and hear a bunch more of the bike. I actually really love the plastics they went to for '87. The shrouds and tank, look so much narrower around the front of the seat area. I thought long and hard about converting my '85, over to the later style. To the point of even getting the different mount brackets from a later frame, to pull it off. I was thinking maybe your bike, has graphics from like an '89 Husqvarna or somethin. You know, when you have a new model of whatever, and then they make a small asthetic change for the next year. It is so so common to see folks update the looks of there whatever. So it can still look like the latest greatest model.

Anyhow, can't wait to see more of your bike. Looks like quite a fantastic dream example to me.

 

['87 500XC]

Can't wait to see and hear a bunch more of the bike. I actually really love the plastics they went to for '87. The shrouds and tank, look so much narrower around the front of the seat area. I thought long and hard about converting my '85, over to the later style. To the point of even getting the different mount brackets from a later frame, to pull it off. I was thinking maybe your bike, has graphics from like an '89 Husqvarna or somethin. You know, when you have a new model of whatever, and then they make a small asthetic change for the next year. It is so so common to see folks update the looks of there whatever. So it can still look like the latest greatest model.

Anyhow, can't wait to see more of your bike. Looks like quite a fantastic dream example to me.

Thank you for the kind words. The graphics are actually hand done. I asked my father about it and he didn't like the yellow side panels and stuff so he changed them to white then made the yellow and blue stripes like you see them. Once the bike is back together you will see that the stripes go up and over the fender and wrap around to the other side.

But it has all original plastics minus the front fender I believe, that was changed to an aftermarket Acerbis most likely due to a crash.

Updates will be coming soon once I receive my box of parts.

 

[1Tuff500XC]

Good deal, look forward to seeing the custom graphics, as they so far look very appealing, and OE like. I was really thinking he must have just snagged slightly later OE decals.

Where are you getting parts for the bike? I know you can still locate the OE 100% correct NOS front fenders. Rad shrouds are quite scarce in NOS form. Tank is availabe NOS, as well as side plastics.

 

['87 500XC]

Good deal, look forward to seeing the custom graphics, as they so far look very appealing, and OE like. I was really thinking he must have just snagged slightly later OE decals.

Where are you getting parts for the bike? I know you can still locate the OE 100% correct NOS front fenders. Rad shrouds are quite scarce in NOS form. Tank is availabe NOS, as well as side plastics.

Yea, I was curious so I asked him and he said he just hand layed some vinyl.

All parts so far, which I got in the mail today, I have gotten from Phillip @ http://www.husqvarna-parts.com/page/page/3737813.htm

He is awesome and knows his stuff. Fast shipper as well.

Updates will be coming soon as I just recieved my parts today.

 

['87 500XC]

Update: Got parts in, here's some pictures below of some various unique pieces on the bike like the clutch linkage I told you guys about and the etched cylinder head by Up-tite plus the V'd out swingarm ready for some Tig weld.

 

['87 500XC]

And here's pictures of the parts I got.

Parts list includes:

Front and rear brakes
Parts listing manual
2 stroke engine manual
Sprocket cover decal
Brand new NOS water pump housing (just incase as there as scarce as hens teeth now)
Water pump O-Ring
Uni-Filter (couldn't find a twin air...)
Front and rear sprockes (14/54)
updated swing arm needle bearings with integral seal
Ohlins single shock rebuild kit
Ohlins single shock sticker kit
WP 40/54 fork seals
And a chain guard pad that goes infront of the swingarm that is on its way(not pictured)

 

[1Tuff500XC]

Great pics. Wow, I really like this bike, alot. I'll go back and re-read the prior info, as I'm curious about the clutch linkage you referenced and the pic. Fantastic bike. About the most trick, and clean late 500 2T I've seen. Sounds like a monster power wise. Shows what is possible. Can't wait to see/hear more.

Think you'll have any chance at some Youtube clips, so others can here how she sounds, and maybe see her under power???? Would love to see that, and, on youtube, footage of Husqvarna's are very rare. Just a few. No pressure, just curious, and would love to see it.

Thanks for the update info/pics. I'm thoroughly enjoying this, and its making me ultra anxious to get to work on mine.

 

['87 500XC]

Great pics. Wow, I really like this bike, alot. I'll go back and re-read the prior info, as I'm curious about the clutch linkage you referenced and the pic. Fantastic bike. About the most trick, and clean late 500 2T I've seen. Sounds like a monster power wise. Shows what is possible. Can't wait to see/hear more.

Think you'll have any chance at some Youtube clips, so others can here how she sounds, and maybe see her under power???? Would love to see that, and, on youtube, footage of Husqvarna's are very rare. Just a few. No pressure, just curious, and would love to see it.

Thanks for the update info/pics. I'm thoroughly enjoying this, and its making me ultra anxious to get to work on mine.

Thank you for the kind words.

As far as clips go I won't be actually riding it until the spring and hopefully I'll have a helmet cam then. I'll probably post up a video of the first start since 1996 though haha.

 

['87 500XC]

Another update, got the countershaft sprocket on. When I got it the circlip wouldn't fit. Took it apart and everything looked fine. Measured the old sprocket width to the new sprocket width and the new one was .024" larger and had a .002" offset. So I machined off .012" from either side and made it into a 0 offset. Put the sprocket on circlip on and with 2 hits of a hammer using a 1" socket over the shaft the clip poped right on and seated nicely.

Then I put on the sprocket cover with the brand new decal, looks very sharp.

Also measured my fork drop before I remove them to service them (left side is .003" higher as of now)

Then I checked the TQ on the cylinder head and marked it to show if it moves.

 

['87 500XC]

Factory Connection did not want to attempt to take the rear shock apart so my father did it instead. Who says you need special tools. Took him 20 mins.

 

[1Tuff500XC]

Awesome!

 

['87 500XC]

Awesome!

Swing arm is welded, pix to follow soon.

 

[1Tuff500XC]

Fantastic, I'm even looking forward to that.

Are those front forks just from say a 1990 model, or so????

I've not really caught on to loving the upside down forks, in general, but these WP's are bout the best looking ones.

I have '98 RM Showa Twin Chambers for one of my bikes, and the WP 50mm Extreme conventionals for the other bike.