1979/80 CR390 Works Hybrid Project - Passion Inspiration Action

Rear Wheel before and after!

I knew that I wanted a better wheel on the back of my 1980 CR 390 project. Aim was to find a 83 XC wheel and use it . Better Wheel. Better Hub. Better brakes...LOL! 18" over 17" running in the longer 1980 23 1/4" swingarm.

The Ebay search started. I actually bought three wheel sets before I found enough good usable parts to make what I wanted...

Here it goes from start to finish

Ebay wheel 430 XC




Top view of spokes and wheel


Side views.. needs work..


Did someone take a side grinder to this wheel or what??? I have never seen a wheel marked up like this!




Nastiness:


Rust in hub after cleaning:




Now lets strip this thing and start making it look new again:


After Black coating and with new Motion Pro Rim locks (x2):






And a freshly turned Hub!!!


Addition of a New Trelleborg SuperMaster courtesy of GoFasters!






Look how smooth that wheel is now!


And now for Custom "Made Special For Me" Rim decals by Roost MX





And one last shot - Ready for new sprockets and Quality German bearings



Just wait until you see the brake backers for this wheelset.... this is really getting fun now!

T

Front Brake Backer and DSL Rebuild

Ok .. I now have all of the components ready for install . Pretty much all refurbished and/or new components. Dull electroless Nickel for corrosion resitance and superior aesthetics. New pads. New adjuster arm. Complete blast and fresh powder. Mobil 1 Synthetic Grease. Nickeled springs. New clevis pins. New SST Nyloc nuts. New SST snap rings. New pads.

Components ready for reinstall:


Cleaned posts:


Greasing Cams/excenters with Mobil 1 Synthetic


Installing excenter:


My helper:


Install Orings:


With both brake excenters:


First Brake arm:




second brake arm:


Pads with springs:


New casting needs flash removal before install:


Dont forget the brake stay arm bolt:


New snap rings:


Install new SST snap rings 11mm x 1 mm


pads now complete:


Brake arms now complete:


Install adjusting arm:


Inside now complete:


Outside now complete with all new hardware ( note - will be swapping out for cotter pins on clevis pins):


The complete front wheel ( still needs quality German bearing install)



T

420 SST External Retaining Snap ring 11mm x 1mm

McMaster-Carr 562 692 5911

item # 90967A165

Bag of 5 $3.62

They fit very well.

T

O-rings came from Phillip @ husqvarna parts. Honestly did not measure them. Anyone?

T

FRAME /SWINGARM BARE METAL CLEAR COAT / Titanium effect

Third time is the charm!

I was not happy with the clear coat from before so I did it a third time.

Bead blasted to a somewhat rough finish and immediately clear coated with UV and chip resistant powder and have let it cure out for about 6 weeks.

There is absolutely no color on this frame. This is bare metal, media blasted for effect and cleared.

I wanted a titanium type look with the metal kind of appearing through it.

If you look at the swingarm pic that is up close you will see how the bare metal sparkles through... even though the clear coat makes the metal take on a darker Titanium color. Up close this is just amazing to see. Truly Unique...

Here are some pics:
11 oclock view


My neighbor never waters his lawn...

Side view


Swingarm


There will be more up close shots in the threads ahead.

By the way... White towels courtesy of the Ala Moana Hotel in Waikiki

T

Swingarm Bearing Install Tool

I saw a picture of something similar to this on Yahoo Husky Group. Credit for the design goes to Peter ???

I tweaked it a little bit and made myself a homemade bearing installer.

Bearings will recess to exactly 3 mm for correct depth for O-ring insertion. OD of machined bushing keeps needles in place and tight during install. No hammers, no drifts, no swearing involved.



More swing arm pics in the next thread!

T

Swingarm is ready for restoration!

I now have all of my components

Titanium effect coated swingarm
New German Bearings.
New O-rings
Uptite Chain tensioner with Greasable fitting
Restored DullElectroless nickel plated Motor mounts and swingarm bolt tube
Restored Dull Electoless Nickel plated Swingarm bolt with new Blue nyloc nuts
Restored Dull Electroless nickel chain wear pad screws and washers
New SST chain tensioner arm
New SST swingarm wear washers
Restored Dull Electroless Nickel plated "Quick Pull" rear axle, chain adjusters, spacers and nuts
New Chain Friction wear pad
Home made Bearing install tool
Bearing spacers miked for matching size

Pics as follows:






New SST Tensioner arm... look at the old one... worn out, slopped out hole, thinner:


Restored Chain tensioners:


Restored Spacer:


Restored Axle


Restored axle right side of bike:


Axle Quick Pull:


New Bearings and O-rings


Friction pad bolts before:


Friction Pad Bolts and washers after Dull Electroless Nickel Plate:


T

Sorry Schimm... just saw this... Closed out Disneyland at Midnight last night with the kids and their friends... my daughters 9th birthday ! The Haunted Mansion set up as Tim Burton's "Nightmare before Christmas" was my personal favorite...

With a little luck but more importantly free time during the holidays, I should have a rolling frame complete by New Years.

Swingarm will hopefully get assembled today but have season ender Little League game( i'm a coach on my son's team) followed by an awards Pizza Party.

Then , per the recommendation of George @ Uptite, on to tackle the motor conversion from 1980 CR390 to CR420...making a great motor even better!

T

Hi Moody,

You can find all that you need here in the Vintage Tech ref Section under Service Bulletins... look at thread #2 and open the PDF:http://www.cafehusky.com/forums/showthread.php?t=1526

Only works with the 1980 390 motor. German Piston Source: Wossner

More information in this thread: http://www.cafehusky.com/forums/showpost.php?p=2400&postcount=15

And a direct link:http://www.woessner-kolben.de/

2 stroke page in English : http://www.woessner-kolben.de/english/indexenglish.html

All of this information was originally provided by Tommied

By the way , I never did find a swingarm axle for you.


T