84 WR250 came home today

Yup and I installed a brandy new one. this model only has one o ring,
So Bill, let it leak?

hmm, there were later years that used dual orings..i take it you lubed the oring with a bit of oil to aid assembly? perhaps it was cut on a burr or something when installed. kinda unusual for these to leak compared to the older style seal.

Very good point. I may have damaged it during assembly. I have an extra.

I fix every leak I can. I hate oil leaks.

me too, spend all this money and have to deal with an oil stain...... anyway, i ordered a later model shaft with two o rings. let's see if that works.

Fact, oil leaks? I never parked my bandit 1200 near any Harley’s , I didn’t want the bandit picking up any bad habits, (oil leaks). Lol

thats only because the Harley guys wouldnt let you park your Suzuki next to them !!! LOL

Did you get a matched set of cases? Husqvarna quality was top notch but I always recommend matched set and not replacing one half for the reason you just found. You may need to polish the mating OD on the shift drum but that would be uncommon.

Hey Jim,
yes there are a matched set. Installing the shift drum was difficult. There's a bushing over some ball bearings that seemed to be a very tight fit.
It didn't slide in that's for sure.

And yet my 400 and 250 both have mis matched cases and run like champions!

Sometimes it works and others not.From lesser brands I found out the hard way.

I agree that an original pair is preferred, they're getting harder to find on this side of the pond, shipping $$$ from the US is crazy.
Tony.

I had a couple of case sets that had some unknown quirks. They were matched but for some reason the one set did not like a couple shifter barrels
and would not shift right. All was measured , all seems ok, but I believe some modest run shifts barrels run late on Friday by worker,
before coming home were just a bit off Had a used case I thought was right but had a taper in the right side main. I did not measure taper and out if came to have that was bored and machined and shimmed. And hear this one - had a brand new set of cases for build and of all thing the rear dowel was 1mm wider than stock. I never measured them before. Found that out because the right side inset case bushing was move out , you could barely see it - oh hell swingarm would not fit , out it came and 1mm removed from dowel I now measure, and measure and triple check everything. Most all these had installed sets of crossed parts from all different years

going to check that centering dowel. that seems to be a common screw up when assembling.

To sum it all up. It was a pretty easy resto. It was my first time rebuilding a bottom end so I pretty much second guessed every move.
The shifting issue was the centering dowel on the return spring,,, common but easy to miss. Live and learn.
The shift shaft on this 1984 only had one o ring, i swapped it for a 86 with two o rings, no leaks. I think I may machine another slot in the old one for my 83 430 which will leak also.
Phillip at Husqvarna-parts supplied all the goodies fast and accurate, thank you Phillip for keeping the brand alive!
I'm looking forward to the race season which starts in a few weeks! Thanks for the help guys, have to keep these bikes going.

Well here it is. other that a couple laps around the yard, the first actual ride. Jumped into the first race of the season.
What better way to shake down a bike then in race conditions, 85+ degrees.

Flag dropped in the EVO drum brake class. I was the only left kick bike. Started first kick! Got off the line dead last, who cares.
The old Husky never sputtered once. Jetting was perfect. Motor pulled hard like a tractor!
Most of the course was grass track and lots of tight corners. The woods portion of the event was some rocks but faster whooped out trail.
The down side, the bike is way too soft for my fat A$$. Kinda nice in rocks. It's slightly lower than my yamaha so that's a bonus.
I'm not sure this is the bike for Hare Scrambles, great enduro bike though, what it was meant for.
Brakes were very good compared to my Yamaha IT250. Front was very good.
Overall I was the only Husky out there. Had many guys come over to check out the bike, ask questions take photos etc.
One guy, I think his kids rode Husky 85 minis, came over to show his kids what "Husky's use to look like" . that was cool. I felt like I preserved history a little bit.

sounds great! maybe you just need to set the suspension up a bit better. stiffer springs perhaps? have you set up sag?

slip the spring collet on the shocks down 1 clip, big difference!

Yup, just need some tweaking. also need foot pegs, these things suck!