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Old 03-25-2014, 06:55 PM   #1
FJ_Kevin OP
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FJ_Kevin's CR250, 390 & 430 Vintage Husqvarna Restoration Extravaganza!

Alright boys, welcome to my new Vintage Husqvarna Restoration Extravaganza thread!

I've really done it this time . I have a shop full of beat up old Huskys needing lots of work. The plan is to get them all going, have some fun and maybe even race a few of them .

Now some of you may already be familiar with my "Building a YZ465 Factory Replica " effort. This thread will continue in a similar vein but will instead feature air cooled Husqvarna's of the late 70's and early 80's. The current lineup includes a 1980 CR250, 1978 CR390, 1980 CR390 a 1981 CR430.

I was initially going to chronicle these new efforts in the Yamaha thread but was persuaded by WFOPete that the topic was different enough to warrant a fresh start, so here we are.

One thing for sure though, I will still be tinkering with the big bore YZ/IT's ... they are not going away! And I am eager to see how the Yamaha's and Husky's compare.

I also plan to continue to report on events and races that I attend. At first I wasn't sure as to which thread I would report these to. But I have since decided that this will be determined by which bike I ride. So if I race a Yamaha the event report will go in the Yamaha thread. If I race a Husqvarna the report will go here.

One other thing. I am not a Husky expert by any means. Please keep this in mind as I muddle through all this. And please feel free to chime in with any comments or suggestions. All are welcome!



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My '81 YZ465 Factory Race Replica
http://www.advrider.com/forums/showthread.php?t=772033

My Vintage Husqvarna/Motocross Restoration Extravaganza Thread
http://www.advrider.com/forums/showthread.php?t=964670
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Old 03-25-2014, 07:25 PM   #2
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So let's have a quick look them all before we get started...

First up is this 1980 CR250. It has a stuck motor, blown Ohlins shocks and who knows what else. Here is the 1st snap after arriving home.



Another as it leans against the shop door.



Next is this 1978 CR390 bought off ebay. It has a stuck motor also .



This next one was not a complete bike but rather an assemblage of spare parts collected over time. I had some crazy ideas for this but eventually I realized I had about enough to build something close to a 1980 CR390.



Here is in a pre-build mock up state


And finally is the 1981 CR430. This was a pretty big mess. At the moment it looks like this with a freshly powder coated frame. The motor runs but is on the bench for inspection.



Much, much more to come!





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My '81 YZ465 Factory Race Replica
http://www.advrider.com/forums/showthread.php?t=772033

My Vintage Husqvarna/Motocross Restoration Extravaganza Thread
http://www.advrider.com/forums/showthread.php?t=964670
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Old 03-25-2014, 08:31 PM   #3
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Saw Heikki race a few times.
He was incredible on any Husky he ever rode.
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Old 03-26-2014, 06:21 AM   #4
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Old 03-26-2014, 06:28 AM   #5
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I owned a 1976 CR250 back in the day. Wonderful memories.
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Old 03-26-2014, 06:45 AM   #6
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Go Kevin!
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Old 03-26-2014, 10:31 AM   #7
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Love the old Huskys. I remember back in 1978 I was a kid, had no money and was riding an old Yamaha tt500 at a local hare scramble in SE TN. In pulled this big enclosed van and out came a couple of Husky sponsored riders. They absolutely smoked the field on those Huskys.

Looking forward to the builds.
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Old 03-26-2014, 04:55 PM   #8
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You have got it bad! I could only dream of owning a Husky when I was young, I always loved that classy chrome on the tank.
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Old 03-26-2014, 05:34 PM   #9
FJ_Kevin OP
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More on the '78 CR390

Even though I have moving back and forth between all these bikes most of the recent effort has been on the '78 CR390 and so that is what we will cover first.

Now some of this I have already written about in the Yamaha thread. To bring the newcomers up to date and to have the full story in the same thread I am reposting some of this material here along with a few additional comments. Also included is some of the original comments as I think these too may be of interest to those working Husky projects.

So from the other thread...

Why a Husqvarna?

While I still vastly favor my Yamaha's and always will, I was interested in building a twin shock mxer, specifically a '79/80 twin shock Suzuki RM 250/400 like this one found on the web,



And I think I have mentioned before how I really loved my old RM250...



... but I looked and looked and could just never find one in my area.

Instead, these Husqvarna's kept turning up.

I ignored them at first. Euro crap, I said. I remember riding a friends 390 back in the day and was not impressed. Plus I had Maico's - always a chore keeping those going! But finally I caved and bought one, then another and then another!

I think it was those sexy alloy fuel tanks that got me. Reminds me of my Moto Guzzi Ambassador.

Anyway, for now we are just going to talk about this 390. It is a 1978 that I bought the next town over for $700 after 1st finding it on ebay.

While the price may or may not sound too bad, I was taking a real chance as the motor was locked up. And I knew nothing about the potential evils lurking in the hearts of old Huskys.




More to come...

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My '81 YZ465 Factory Race Replica
http://www.advrider.com/forums/showthread.php?t=772033

My Vintage Husqvarna/Motocross Restoration Extravaganza Thread
http://www.advrider.com/forums/showthread.php?t=964670
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Old 03-26-2014, 05:40 PM   #10
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Quote:
Originally Posted by anonny View Post
You have got it bad! I could only dream of owning a Husky when I was young, I always loved that classy chrome on the tank.
I agree, always liked the color schemes, especially the red with the green number plates. And I really favor the CR models with those alloy tanks.

"On Any Sunday" and Malcolm Smith was a big influence too!



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My '81 YZ465 Factory Race Replica
http://www.advrider.com/forums/showthread.php?t=772033

My Vintage Husqvarna/Motocross Restoration Extravaganza Thread
http://www.advrider.com/forums/showthread.php?t=964670
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Old 03-26-2014, 07:06 PM   #11
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All right! Another FJ_Kevin build-info-entertainment thread!
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Old 03-27-2014, 06:34 PM   #12
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I'm no Husky expert by any means but I seem to remember the black tank was the OR model... CR engine tuning with WR gear ratios, intended for desert. 17" rear rim. Or something like that.
I'm sure I'll be corrected by the experts.
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Old 03-27-2014, 08:02 PM   #13
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Quote:
Originally Posted by ericm View Post
I'm no Husky expert by any means but I seem to remember the black tank was the OR model... CR engine tuning with WR gear ratios, intended for desert. 17" rear rim. Or something like that.
I'm sure I'll be corrected by the experts.
Hi Eric,

Apparently the CR390's, WR 390's and OR390's all came in black at one time or another.

Here are some of the brochures I found on the web while researching these project bikes.

First is the 1978 CR390 like mine, notice the small alloy tank.



This next one shows the WR390 in the upper right (250 is on left). The tank is larger and in steel. The gas cap is centered on the steel tanks and offset to the right on the alloy CR tanks. The WR's have the lighting kits also. I believe this is a 1979 or 1980 brochure as these show the updated frame (with extra tube running in front of the updated air box).



Next is an OR390 with the earlier frame like my 78 CR



And now here is the OR 390 with updated frame like the WR posted above. Looks like this version came with Ohlins shocks too. I think the OR's have the larger capacity steel tank as well. No lights though.



I believe this next one to be a 1979 CR250 (the 390 would have a black tank). It has the updated frame and air box, the alloy tank but still retains the rear fender loop. Also notice the left lower corner of the seat forms a near 90 deg angle.



The 1980 CR has the update frame and air box, the alloy tank but drops the fender hoop. The seat tubes have a kick up at the back as does the seat.



It is a bit tricky to get the correct seat cover for 1978,79 and 80 model years. Took me awhile to figure out why my new seat cover didn't fit my seat! More about that in a future post!




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My '81 YZ465 Factory Race Replica
http://www.advrider.com/forums/showthread.php?t=772033

My Vintage Husqvarna/Motocross Restoration Extravaganza Thread
http://www.advrider.com/forums/showthread.php?t=964670
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Old 03-28-2014, 04:26 PM   #14
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More Husky material from the other thread

So let's have a closer look at the beast for some 1st impressions,



Again, this is a CR model, Husqvarna's designation for the motocross model.

They also came in WR (wide ratio or woods racer?) and OR (off road) versions as shown in the previously posted brochures.

My understanding is the CR model came with increased suspension travel and a close ratio gearbox. I believe the pipe is a bit different too. The WR seems to have a larger silencer and may be double walled in some sections to soften their bark.

I am finding out that the '78 CR390 is quite similar to the '77 version. I believe the frame is essentially the same. However, the '78 came with the vastly improved Timpken tapered steering bearings while the '77 still sported loose balls (always a dangerous practice ).

All the Husky's of this era were pretty attractive in my mind. Black with yellow plates was the color scheme for the big bore CR390 while the 250's used Red with green plates as shown in the following photo.




It turns out that the choice of number plate color was not really Husky's. In fact, they were simply following the requirement of FIM Grand Prix motocross that all open bikes run yellow plates with green reserved for the 250 class.






CR390 Suspension

This particular bike came with non-original S&W shocks which I think are early versions of the Progressive brand shocks sold today.

I am not quite sure what shocks it came with originally as some articles seem to indicate Girllings while others mention Ohlins for '78.

Currnut shocks were another shock supplied on Huskys but I don't thing they were used on the CR motocross bike. I know we have a Currnut expert in the 2-stoke forum, perhaps he can chime in here with some more definitive information .



I did begin to formulate some opinions upon closer inspection of the bike. I have to say I thought the top shock mounts looked rather light duty. Shock bolts looked undersized too.

Same with the swing arm mounting plates. They looked pretty thin to me. No extra gusseting around the bolt like you sometimes see on motocrossers from other manufactures.

I have read about ovalizing of the swing arm bolt hole if not keep tight and I can now understand why. Fortunately, this one hasn't suffered this problem.

Compared to the Yamaha's, I thought the swing arm and rear axle diameters were undersized too... same for the wheel bearings, hmmm.

The front end was also a bit disappointing as the front fork tubes are only 35mm. According to Dirt Bike front travel was 9.5 inches. I remember the tube diameter as being a major knock on Huskys of this era and I must say they look pretty whispy compared to the 43mm forks on the Yamaha's. I was thinking a fork swap could be in this bikes future. However, now I think I will just keep this one stock where possible. I'll try my experiments on that piece meal '80 390 .

More to come...



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My '81 YZ465 Factory Race Replica
http://www.advrider.com/forums/showthread.php?t=772033

My Vintage Husqvarna/Motocross Restoration Extravaganza Thread
http://www.advrider.com/forums/showthread.php?t=964670
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Old 03-28-2014, 05:15 PM   #15
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Alright, so I already mentioned that the motor was locked up on this bike. I suppose I was hoping that it was just the top end that was frozen and the crank was OK.

It turned out to be just the reverse. With some liberal application of WD40, the top end cam loose and off will little problem.

Unfortunately, the crank case was full of dried up sludge. It looked like old fuel must have leaked into the bottom end where it all turned bad over a decade or so.

The crank was totally wiped so a full rebuild would be in order.

It is a little bit interesting to compare this Husky motor to the YZ465/490 motors I have been working with.

The Husky layout is a mirror image meaning every thing is on the opposite side. Yamaha has kicker and clutch on right, ignition and counter shaft sprocket on left. The Husky has kicker/clutch on left and ignition and drive on right.

There are other differences too. One key difference to be aware of is that the flywheel nut is left hand thread!

In my search for a crank, I ran across more than one where the flywheel side threaded end was sheared off, likely the result of assuming right hand thread together with use of an air wrench !

Other than the flywheel nut, the cases split fairly easily. I used this case splitter purchase off ebay ($50 shipped) shown in the following photos. It seems to be drilled to work on a few different models and worked just fine. I guess I should have made one but I didn't happen to have a large enough piece of steel around. Ah well, I guess I have enough to do.





And of course non the flywheel pullers already on hand worked on the Motoplat flywheel so that was another ebay purchase (~$15 I think).

Unlike the crank nut, the flywheel & puller utilize right hand threads. I'll see if I can find the thread size so others will know which puller to purchase as there seems to be a few different ones available for these old Huskys.




So I am a little short on photos at this point but here is one with the cases opened.





And it gets worse !

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My '81 YZ465 Factory Race Replica
http://www.advrider.com/forums/showthread.php?t=772033

My Vintage Husqvarna/Motocross Restoration Extravaganza Thread
http://www.advrider.com/forums/showthread.php?t=964670

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