85 500XC questions Frank N Tryke

Hello fellow Husky riders!! I am a Husky rider finally after 30 years of Big 4 riding and I am loving it. I have a 85 500XC and am very impressed with power (un)rideability (5th-6th gear yeow!) and so on. Semi-retired Bike & Aircraft Mechanic with way too many tools.
I want to throw out a few questions. It can be hard starting. Almost seems like weak/no spark. Or not enuff fuel charge. Will choke 2-3-4 (or way more) kicks and don't really get a rich start or blubber start at all just an occasional pop!. I just pulled top end down and put fresh piston/ring/bore pretty much freshened all up, intake gskt good reeds etc etc. Intake boot. Verified no air leaks with good old ether CAREFULLY once started. Still starts the same. Was run under good loads and ran it semi-hard before top end fix ... no problems no issues.
Stock 40mm carb jetted with modded intake HUGE K&N. Maybe too lean because of this? However, with same setup, previous owner stated 1(-2-3) kicks with choke to get a full rich semi-start and then 1(-2-3) kicks choke off and bike starts. Cleaned out ignition area blowing all dust etc out, it has SEM with lighting capabilities. "Centered" ignition base plate (from almost, if I remember correctly, full CCW. i will ck marks) per George. Didn't/couldn't get rotor nut loose to pull rotor/flywheel (RH/LH thread? are there any tricks/tools?) to do better cleaning. Should I get it off and clean better?. Slightly... modded stock exp chamber and excellent Answer silencer. I have started many Honda/Yam/Kaw/Zook 500-490's, Desert Racers (ARIZONA) and know the drill, TDC, but have not got the "Husky touch" yet.
Another big Question. Prev owner had trans fail and was rebuilt seems fine. Bought 1 spare motor "cheep" and chunks of gear teeth, yes, came out on mag drain plug. (30wt 1&1/4 qts?) (spec sez 1.6 liters?) blows it out? Uh... a little tranny problem here??? I had to swap clutch inner hub as it was "wobbling" on shaft and clutch outer had big grooves at tab area. Will a 4 speed cr500 trans shaft/gear set/drum fit XC cases? Or would complete motor be better? See I don't really need 5,6 for my application. Yawns here i bet. I'll post a pic that will explain. Please no death threats.

Working on rear suspension (spring) and will send Single Ohlins in to "somebody" who is very good with them. I scored a suspension item, FeeBay, that has not hit my door steps yet that may be prized and will share pics when it arrives.
Will do front 40mm mods once i verify the "hot set up" as some other Cafe threads have great info. THANK YOU VERY MUCH.

Husky Mike. Previously Honda Mike. yes I had a 1979 CBX 6 cylinder Honda Street bike also. Chrome Gold Red RC Engineering. Damn near killed me. You see .... it was fast in a straight line but ..... it didn't turn. Bad things man.

Can't help with all of the points.

Generally the spark is pretty feeble I think the plug gap is like 18 thousands when you convert it from metric. Way different from my pickup truck which is like three times as much and the spark plug box tells how it sparks with the electricity going one way and then virtually instantly sparks with the electricity going the other way which has apparently been going on for about 20 years. I have one with a pvl ignition and it isn't any more impressive.

The four speed is like 2,3,4,5 not like leaving off five and six. Those cases will work for 400, 430 and 500 and any gearset for that vintage. The input shaft has first gear built into it so you must change basically everything. How many teeth are on the back of the clutch 18 or 21? Are they in good shape. In a lot of ways the magnesium itself can become the most problematic as yours sounds like it has been used quite a bit. Metal pieces in the transmission can pretty much ruin everything but the cases and the crank and the electric components and perhaps some kick start parts. Just one of those little needle bearings in the kick start gearing can do it maybe gear chunks aren't as bad.

Nut on electric side of crank is left hand thread, reverse from normal. You need a puller and often it needs a tap to get it to pop off. It has been quite a while since I adjusted anythig over there but I thought you rigged up a dial indicator in the spark plug hole had the rotor loose so you could take it off and turn little screws rotate things put a pin in a hole and then tighten up the rotor. I have noted on prior posts I have engines in the bonepile which those little screws loosened up and damaged stuff so loctite is probably in order on them though I personally havn't had any mishaps on the screws I twisted or used loctite.



Fran

Interesting........

I got one of first 3, 85 500 xc's when they came out. Raced it for 3 years, then replaced t with the 430 MX'er( had to have the upsidedown forks!.....which didn't work well at all.)

Anyway... biggest issue with starting was jetting. Change out to a 7F7 needle with a bb-o needle jet, richer on the pilot, don't remember main....and it becomes a 1 kick hot, 2 or 3 cold. Oh, and grind out the slide to a 2.0 or 2.5.

I put v-force in my air cooled 500 Huskies with good results, I'm sure it would help the water cooled also.

4-speed would fit right in, but then you end up with starting in second, you can only gear a Husky down a little. I have 2 or 3 good 4 spd. clusters. ( I like 5sp or 6speeds in my bikes).

Best thing I found to smooth out the surge of power was an uptite pipe.

More great info/details.........