• 2 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     WR = 2st Enduro & CR = 2st Cross

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

250-500cc WR360 modification - Why? Because it’s fun!

J

Jason Bearham

Husqvarna
B Class
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At the start of the year I purchased a 2010 WR300 with very low mileage on the clock.
It was great fun with a pretty savage power hit which is just the way I like it!
I decided not to modify & try to keep it reliable…

Anyhow it grenaded two clutch activator rods & one activator lever within about 200km riding.
Then I had the carb needle in the 2nd leanest clip trying to sort out 100kph cruise & burnt the head while having a hard play racing mates on a super fun winding 6km long bore drain track.

Sooo the fix for the WR300’s issues was to purchase a 1995 WR360!
Seems great mechanically - just the plastics are in bad shape.

The CDI seemed a bit dodgy so I swapped in the 300’s unit & it starts nice & easy now.
Bike was loads of fun with instant power & row through the gears just as fast as you care to shift!
The previous owner had sent the suspension out to be professionally rebuilt & it is super plush.
The brakes have obviously been given proper love as they are sooo much better than the 300’s untouched brakes.

The exhaust was bent & squashing a coolant hose.
As a quick experiment I fitted up the 300’s expansion chamber.
It raised the power band onset & gave a distinct hard hit.
Lots of fun but it signed off early & went flatter than with the original pipe, so I took it off again.
I repaired the first bend out of the head on the original 360 expansion chamber with a piece I cut out of the emissions pipe that came with the 300. It probably made no difference to performance but the exhaust pipe is no longer squashing a radiator hose.

I rode it a few times with the original Delorto carb & it ran alright but I figured it could be better so I swapped in the 300’s TMX 38 Mikuni.
I had previously done the Jarvis mods. I changed the idle to 70 upped from 50, the pilot to 27.5 down from 45, & upped the main to 440 from 430. I also put the GAY needle into the 2nd richest position this time…
It runs much cleaner & revs out just a tad further.

The clutch had no more available cable adjustment & had to be pulled all the way into the hand grip to disengage so I pulled the cover for a look. I mixed & matched 300 clutch rod head with 360 rod & got the adjustment I needed.
I also lubricated the cable.
Now I can feather the clutch with my index finger & I feel like I’ve got some proper control again.

I’ve read up on the Wallybean intake mods & decided to take a look at the intake tract.
After removing the intake & reed block I decided to scrap the reed stuffer & install the 300’s intake boot.
It’s not a straight swap but easy enough to adapt on if you are prepared to be creative. Could definitely be done neater than I have currently done…
Of course the intake swap meant that I had to swap in the 300's airbox and its carb connecting duct thingy.
Anyhow - WOW - goes like a cut cat & revs out much higher & very cleanly.
It’s a real gorilla now! Big power everywhere!

I’ve got a couple of tuning tweaks left to try & then I’ll swap the motor into the WR300 chassis - well that’s the current plan…

Cheers,
Jason
 
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So yesterday I spent some time & swapped the WR300 expansion chamber back on to the 360.
It did fit last time but the port angle in the head is different so it wasn’t particularly great.
I twisted the 300 pipe just a tad so that it fits cleanly into the head.
Neither the 300 nor the 360 muffler lines up properly with the mount holes on the subframe so I just wire tied the 300 muffler in place for the purpose of testing.

It completely TOTALLY changed the power delivery!
Last time I still had the original Dellorto carb & original unmodified intake boot with reed stuffer & I found the power hit hard but just fell on its face very early.

To recap - Now it has the WR300 CDI, expansion chamber, intake, Mikuni TMX 38, airbox & the reed stuffer is removed.

The 360 screams now!
It has a very hard power hit like the 300 & in my opinion revs out faster & just as high if not higher rpm than the 300.
I had SO much fun thrashing it around this afternoon!

The difference between the two pipes is huge - but - they are both heaps of fun to ride with!
The 360 pipe is on song right off idle & the engine feels incredibly strong. You can feel it signing off but still has plenty of over rev. It’s a riot to ride in this configuration.
The 300 pipe waits for a few more rpm before coming on with a crazy rush & the rpm zings straight to the moon. The adrenaline rush is addictive…

With either pipe it feels like it is on the rich side so I’ll carefully test a size smaller jet.
I will make an adapter to properly bolt up a muffler instead of tying it on with wire…

Cheers,
Jason
 
It’s a riot to ride in this configuration. The adrenaline rush is addictive…
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I know the feeling. Making improvements on these old bikes is where the fun is for me too at this time seeing as I can't ride much any longer. Glad to hear someone else having so much fun making modification on these older bikes. :thumbsup:
 
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