1985 CR500 Project Bike by Husky 37

Carb: clean up... well perhaps a bit more...

I started on the Carb this weekend.... it has suffered from a storage problem I had...

Still here are some before pictures. It shouldn't take too much to get it sorted... just the usual elbow grease.

Stu

Front end: USD

As you may or may not know I am trying to re-build my '85 500 to be like the '84 Work machine of Leif Persson in this thread below:-

http://www.cafehusky.com/forums/showthread.php?t=5816

The main difference is the front end being Ohlins USD... but I can't find any so the next best thing is a set of WPs.

I do plan on having them re anodised Blue so that they look some what the same, from a distance, on a dark night in the rain...

I still need to do more work on these but here's a taster....

Many thanks to Picklito for his assistance on how, what's best for a front end swap out.

Full details of all the parts will be posted once they are ready to be fitted.

Stu

Carb now clean....

Attached are the before and after pics of the Carb clean (first round) haven't finished it yet but I 'tweaked' my back this afternoon so I find standing bent over a bit of a problem.

Pic 1: Before
Pic 2: After

I will replace the fuel line and the 'vent' tubes shortly.

Just waiting for some different parts for the forks so I can fit these up prior to sending the frame for powder coating...

Stu

That has to be my least favorite job - cleaning carbs.
Funny you say about tweaking your back, me too!
I've been working ever so slowly on my project because of that.

Sorry to hear that. It does seem to slow you up. Funny thing is I've had a dodgy back since '78 but it never went whilst I was racing ......

Stu

Forks: First fit up....

I think Schimmelaw is giving us all a master class in detailing on his project.... puts my effort to shame so I hope people don't get too bored...

I mentioned previously that I needed to do a little more on the forks... Well I wasn't happy with the set up on the complete front end in Pic 1. That was because they were Honda CRF clamps and not the KTM's I had in mind...

To cut a long story short I sourced a pair of clamps from a 2002 520 EXC (Which was what I was told) which were 54mm top and 57mm Bottoms with a 20mm Offset.

One thing you have to watch with fork swaps (which Picklito and Schimmelaw have highlighted) is that the length of the stem can cause problems... and you have to end up putting a spacer in.

Stock KTM bearings slotted straight in.

In Pic 2. the stem length is just about right which makes the swap that much easier. I have limited access to a machine shop so swapping or making new stems is not an option. The only issue is that if you look at the fork stops they contact the clamps very close to the bolts... not ideal but you can live with it.

There are a couple of things I want to do (source brake pipe guides etc) before I break it down and strip the forks apart ready for anodizing.

I think the frame will go at the same time so I get start assembling once they get back..... should take about the same time to do.

Stu

Engine status: Nearly back together after balancing... more pics on that soon.

Stu,
White Power forks, KTM top and bottom triple clamps and the stock KTM stem mount right in the Husky head tube w/ KTM steering bearings/races? No issues w/ the length of the stem. No spacers/bushings required? Lucky you
Nice conversion! Powder, polished or anod triple clamps? What color? Any contact w/ tank?
Great progress. I for one am not bored at all! Love to see what others are doing and how they are doing it. (Maybe I can pinch something from someone) Keep posting up.
Rick
Oh yea, there are some rubber fork stops out there which might cushion the contact between the fork and stop better than those white plastic plugs.
Rick

Hi Rick,

Thanks for the comments, much appreciated.

As I'm trying to replicate the 'look' of the '84 works bike the clamps are going to standard (although cleaned). The legs however are going to be anodized Blue in keeping with the Ohlins on the works bike.

I've done a fair amount of checking on the stem issue and found that the stems are generally 244mm in length which is too long. Picklito found a set of KTM clamps which also had the right stem length which I believe were early ones.

The part no on the clamps is not recognised in any parts catalogue I have access to so I have a guy I know who in the parts department for a KTM dealership email the factory to find out exactly which model it came from or where it was used.

Thanks for the tip on the rubber stops. I going to have some white nylon ones made any way because they are used in the rear frame so we'll see what happens when the time comes.

Stu

excellent mate ! if (which i doubt) you find anything in OZ that they wont post out, let me know and i'll forward it on if you like !

Hi rabskyline,

How about some sun shine

Thanks for the offer and if there's something in the UK feel free to PM me.

Stu

Powder Coating....

Frame and sub-frame taken to powder coating man along with some smaller bits... should be back next week.

Finally see some progress......

Next thing is taking the forks apart to anodize them... need to do that soon so all the bits come back at the same time...

First - nice job. Really enjoying your build up. I like that it's gonna be a rider.

Second - I got lucky. Have both 91 and 93 KTM 500 WP complete front ends in the garage. One day decided to bolt one on to my 81 Husky and see (hey - old husky with USD forks and a disc? That's gotta be cool, right?).

First one I tried was the 93 KTM set. Complete bolt on as far as stem and bearings are concerned, but the 81 Husky's frame-mounted steering stops conflicted with the 93 KTM's steering stops which are on the lower triple. So I looked at the 91 parts... 91 KTM used a frame-mounted steering stop just like Husky, so the 91 KTM lower triple has no stops to get in the way. So off came the 93 parts and on went the 91 parts. Done. No mods needed.

For the record, 89-91 KTM has the correct clamps, stem, and steering stops. 00-02 has it, as does some of the newer stuff, but in between there (92-99) KTM juggled stuff around like hot potatos. Gets pretty complicated unless you're familiar with KTM from that era. For example, although the 91 and 93 parts I tried "look" identical, the 92-94 WP forks had a larger 57mm diameter at the lower clamp, the 89-91 forks are 54mm. So mixing and matching from year to year is pretty messy. Try to find a complete bike parting out and buy the front end. OK - back to you, Husky37...

Hi Picklito,

I hope others that are thinking of putting a set of USD's on are reading this because that's very useful information you have come up with.

If you are lucky enough to catch a complete front end then great but if not and it needs to be pieced together then sticking to one manufacturer can lessen the problems..... unless as you say KTM had a bit of a 'change it for no reason' period..

The first attempt at the front end had CRF, RM and Husky bits.... I sent that back and started sourcing all KTM to match the legs.... some from ebay (I'll admit) others bits from contacts.... and now I have something I am happy with and most importantly, confidence in that it's not going to fail when I'm on it... As you said this bike is for 'go' and not 'show' (same can't be said about the rider but we are working on it )

Stu

Frame - Powder Coated

I managed to get my frame back just before the Christmas shutdown so I could do some work on it....

Pic 1: Before - Tank and Engine
Pic 2: After - Nice and Shinny...

I have also got the Fork tubes back.... now anodized Blue to match the 84 GP bike

Pic 3: GP Bike - Reminder picture
Pic 4: Fork Tubes - Colour in the picture may seem different but it's the same blue as my Renthals (that are on the GP bike) The guys matched it spot on.

The next job is to re-assemble the forks with new seals and mount.... looking to get that done during this week.

Ha! We all have to work on that one!
If there's anything I can do to help with KTM info you guys let me know.

Hi Picklito,

I have the final piece of the puzzle to pick up this week I hope.... and that's the front wheel. I should have the complete KTM front end then as you advised.

Shouldn't take too long to get it put together and post the pictures.

One thing I did find though... the black brake tube retainer which sits between the mud guard and the bottom clamp. A secondhand parts company on ebay wanted £12... direct from KTM £1.40!! sometimes checking with the OEM can save money. Some other parts like the spindle was the same price new from KTM as people were asking secondhand... so guess what I bought it new....

Stu

Very good points... always check for the original stuff. Some of it's still available. There's always a lot of Husky stuff on eBay jacked way up... that's still available right from the dealer or other over-the-counter sources. It pays to check around!

Forks fitted....

Had a chance today to fit up the forks and wheel for the first time (with all the parts I wanted, new seals in forks etc).

Pic 1: Forks fitted to frame - They will need to be removed for greasing but I wanted to make sure everything fitted and I couldn't wait to see how the forks looked

Pic 2: Went a bit further and fitted the mud guard too... I know it needs to come off again but I couldn't help myself...

Pic3: Frame Stem - As I bought these forks in bits, different bits from different people, I have had to go to KTM direct for some bits. If you are contemplating such a conversion I would suggest that whatever make/model of fork you decided on, try and get the complete front end. It will save you a lot of time and money in the long run.

As this is a KTM front the 'Steering head cover' (New shinny bit under the top clamp Part No. 54201086000 (£1.80) and the 'Steering head gasket' Part No. 5460118400 (£2.05) covers the top of the Husky head stock just right apart from where the back tube is welded. As you can see from the picture I cut the back off so it would not interfere.

Pic 4: I put the tank on to show the clearance on full lock.

Next will be fitting the engine back in the frame so I need to get some new bolts....

Stu

Pic 3: Nice mod!

Your new forks look super, Stu. They replicate those shown in the photo of Leif Persson's works bike very nicely.

I appreciate the info that you and Picklito have shared from your USD fork swap projects ... many issues to watch out for. Now I remember why I didn't pursue an engineering career.