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Old 12-14-2014, 07:20 PM   #1
dhallilama OP
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Joined: Apr 2012
Location: Portland, OR, USA
Oddometer: 384
'96 Husqvarna WXC 250 build... all-purpose off road bike

a few months ago, i got the urge for a "modern" woods bike. i started looking at the orange bikes, '00 up YZs, KDXs... none felt right.

then i rode a 90s Husky 250. it felt just like a bike i'd ridden and loved 15+ years ago; a Cagiva. makes sense as that's basically what it is. it's modern by my standards, has a SIX speed wide ratio, built like a brick shithouse, relatively low weight, 130 watt stator... and cheap.

research just fueled my desire for one. came across this cosmetically challenged roach. it had been for sale for a month or so, with no bites. the only problem is it was a few hours away, and my wife was 9 months pregnant. no way was i gonna go look at the bike. kept looking for one closer, but nothing. emails went back and forth between the seller and me, some horse trading happened and it was mine. site unseen.

an inmate was awesome enough to pick it up for me on his way to get another bike. we met up and rolled the POS onto my trailer. i was actually expecting far worse... it's a beater and needs a lot... but still better than expected.

the bike came with a stack of recent receipts- re-plated jug, weisco top end kit, etc.

i've only given it a quick once-over so far. my garage is very full & falling apart, and there's a newborn at home... so this will take a bit of time to do a full build. a few kicks and it started/ran smoothly. good enough, now to tear the bike down 100%.

this is going to hopefully be my main off-road bike... woods, desert, neighbor's front yard...

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current: '89 suzuki gsxr 750 '77 yamaha IT250 '67 harley xlh chopper (3) suzuki jr50 '62 bird mini
project: '96 husqvarna wxc250 '69 harley xlh resto '31 ford

dhallilama screwed with this post 12-14-2014 at 09:04 PM
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Old 12-14-2014, 09:01 PM   #2
dhallilama OP
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Joined: Apr 2012
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Oddometer: 384
more crappy pics...



steering lock... did they all have these????





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current: '89 suzuki gsxr 750 '77 yamaha IT250 '67 harley xlh chopper (3) suzuki jr50 '62 bird mini
project: '96 husqvarna wxc250 '69 harley xlh resto '31 ford
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Old 12-15-2014, 07:04 AM   #3
imsroll
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Location: Pahrump, Navada
Oddometer: 44
whats with that swing arm bolt? is it coming out or is it just that much too long? Should be a whole bunch of fun though. There are quite a few parts out there for these bikes. good luck however finding plastics for them.
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Old 12-15-2014, 09:41 AM   #4
dhallilama OP
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Quote:
Originally Posted by imsroll View Post
whats with that swing arm bolt? is it coming out or is it just that much too long? Should be a whole bunch of fun though. There are quite a few parts out there for these bikes. good luck however finding plastics for them.
swing arm bolt = ankle eliminator. it's way, way too long.

plastics, no problem! DC is starting to reproduce them for the '95+ 2 stroke huskys. i just heard from the owner (and i suspect only employee) of DC about it. they'll be available next month sometime, any color.
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current: '89 suzuki gsxr 750 '77 yamaha IT250 '67 harley xlh chopper (3) suzuki jr50 '62 bird mini
project: '96 husqvarna wxc250 '69 harley xlh resto '31 ford
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Old 12-15-2014, 10:35 AM   #5
BenMcG
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Quote:
Originally Posted by dhallilama View Post
swing arm bolt = ankle eliminator. it's way, way too long.

plastics, no problem! DC is starting to reproduce them for the '95+ 2 stroke huskys. i just heard from the owner (and i suspect only employee) of DC about it. they'll be available next month sometime, any color.
Nice pickup and awesome to hear on the plastics!
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2004 KTM 950 Adventure 2000 Husqvarna WR360 1999 Husqvarna WR125 1994 Husqvarna WXC250
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Old 12-15-2014, 11:17 AM   #6
imsroll
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Woah new plastics sounds awesome. just hope there not $200 for a front fender ect...
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Old 12-15-2014, 11:30 AM   #7
AlpinaE24
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Sweet, mine is still hibernating waiting for me to split the cases and replace the countershaft. Maybe I'll do it later in the week when the KX is back together
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2000 KX250 - Plated
1995 Husqvarna WXE250
1985 XL600R - Sold
1994 XR650L - Sold
2000 XR650R - Plated - Sold
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Old 12-15-2014, 11:33 AM   #8
dhallilama OP
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Quote:
Originally Posted by imsroll View Post
Woah new plastics sounds awesome. just hope there not $200 for a front fender ect...
$65ish for a pair of side plates
$65ish for a pair of radiator shrouds

don't know if they're gonna make a front fender, but I've tried three others (2 Yamaha and a Kawi) that all fit/look good, so not worried about getting a "correct" one.

looks like just about every part is available for these bikes. not as easy as strolling down to the local bike shop or nearest dealer... but online, anyway.

Fork bushings/seals, Brembo master cylinder reseal kit linkage bearings/seals and new sprockets on the way... going to keep tearing it down. strip/paint the frame and replace/repair/refurbish as it goes back together.

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current: '89 suzuki gsxr 750 '77 yamaha IT250 '67 harley xlh chopper (3) suzuki jr50 '62 bird mini
project: '96 husqvarna wxc250 '69 harley xlh resto '31 ford

dhallilama screwed with this post 12-15-2014 at 11:51 AM
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Old 12-24-2014, 12:03 AM   #9
dhallilama OP
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casually looking further... bike needs quite a bit of lovin'
  • lower motor mount broken off frame on one side, bird crap weld on other
  • lower pipe mount broken off frame, bird crap weld left behind
  • steering stop broken off frame
  • foot peg pivot holes are hogged out, nearly worn through
  • kick starter pivot hole is hogged out
  • rear linkage bolt is about an inch too short (no nut!)
  • rear linkage bearings shot
  • fork seals doing a fine impression of a rain bird sprinkler
  • [insert more here as found]

also has some apparently new parts:
  • top end looks minty fresh (only pulled head)
  • stator
  • coil
  • cdi
  • cables

further, the takasago excel rims rims are actually true and in great shape & the Showa rear shock looks sound/sealed.
__________________
current: '89 suzuki gsxr 750 '77 yamaha IT250 '67 harley xlh chopper (3) suzuki jr50 '62 bird mini
project: '96 husqvarna wxc250 '69 harley xlh resto '31 ford
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Old 12-24-2014, 09:51 AM   #10
AlpinaE24
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sounds like fun! I feel slightly better about my bike just needing a counter shaft and right side case repair
__________________
2000 KX250 - Plated
1995 Husqvarna WXE250
1985 XL600R - Sold
1994 XR650L - Sold
2000 XR650R - Plated - Sold
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Old 12-24-2014, 05:58 PM   #11
dhallilama OP
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Location: Portland, OR, USA
Oddometer: 384
Quote:
Originally Posted by AlpinaE24 View Post
sounds like fun! I feel slightly better about my bike just needing a counter shaft and right side case repair
on the plus side, i'ma welder/fabricator... so this stuff is free(ish) to fix...
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current: '89 suzuki gsxr 750 '77 yamaha IT250 '67 harley xlh chopper (3) suzuki jr50 '62 bird mini
project: '96 husqvarna wxc250 '69 harley xlh resto '31 ford
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Old Today, 09:09 AM   #12
AlpinaE24
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I got inspired to work on mine yesterday, cleaned and resealed the whole intake and carb. Also did a cold compression test and got 185psi, put it back together and took it around the neighborhood. Lots of fun with the 6 speed, I really enjoy working on it too...everything just fits together much nicer than my Japenese bikes
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2000 KX250 - Plated
1995 Husqvarna WXE250
1985 XL600R - Sold
1994 XR650L - Sold
2000 XR650R - Plated - Sold
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