86 500 xc

Getting started on brake calliper mounting bracket. It will adapt the 2piston brembo caliper to the SX forks. Simplicity is key.

Well it's been a while bit think I found a cheep used piston and jug that will get me up and running. It's an 86.5 mm weisco piston and the cross hatch markes look good. Decided to pull engine out and start the tear down...well not complete just going deep enough to replace left and right crank seals, for now...
Pic of old jug and piston.

Primary cover removed, has a good pump impeller but is leaking from weep hole at water pump. Just replace the seal?

What oil should I use in the primary?

im using ATF -F (for the early ford Borg warners). seems ok so far, change it regularily

Oh. Ok. It had, best I can tell, 40 r 50 weight motor oil in it....no wonder the clutch dragged so bad. Had to hold on and drop it into gear, holding the rear break only killed the engine.
Thanks

the husky clutches can be draggers... give the plates a scuff up in some petrol and 400# wet and dry. not too much sanding, just enough to remove any shiny glazing.

So I'm a bit concerned...reading the manual on this site, it says there were washer between piston and con rod bearing. When I pulled the wrist pin I had it layed on its side, pulled piston off then bearings out...never saw a single washer! It definatly didn't make it to my bench. I really doubt they could have made it to the crank case...but... I orderd the "gasket set" plus part and right crank seals from vintage husky in AZ...does that set include all gaskets and seals needed to split the cases? I want to KNOW that there are not a pair of washers floating around in the crank case!

stick a magnet probe down the cases, soon find the washers if they are there (unless they are alloy...idiot I should have thought of that....)

Great to kno! It didn't look like there ever was any...
I'm trying to pull the mini6 motoplat off but do not have the puller. Is there a mother way to remove it? Have several pullers but none will fit this app...

Got the clutch discs sanded down. Soaked the clutch discs in ATF. Used 400 grit wet with ATF and lightly scuffed them.

i see it has a 6 bolt clutch..doesnt that mean its 87-88?

may have been an upgrade/fix. I see where something catostrophic happened that pushed the kick gear thru/out of the case. Needless to say the hump around it was broken out, apearently in several pieces. I asume it had something to do with the clutch. Hence bn a newer unit???
All title paperwork and vin # show as 86.

Got the frame primed.

Still need to add some gussets at the front motor mount cross tube to the wishbone, under seat and build a battery box(for ligts). Gasket set came but no water pump seal. Gotta get that coming tomarrow.

Got needed seals and circlip for water pump, coming. I'm glad I ended up getting another jug! Sat down to map my ports for porting. I quickly realized this sleeve is nothing more than scrap! It cracked from notch in bottom thru to closest pot and the web at the bottom. Funny how things work out.

nasty

looks like someone dropped it

May have been from a drop but its been that way for a long time then. My pops has owned it for the last 10'r 12 years and he never had head off. The piston had contact marks in the corresponding place. Can see where it has worn more on bottom side of crack.

With it being a 6 bolt clutch what do I look for in the way of replacement parts? The inter clutch hub is showing signs of eminate failure, several of the lugs that the springs bolt to have cracks aground the base. Also the primary cover has been repaired with jb weld or similar, looks like one of the origional bolts broke and the spring pushed the bolt head out to contact the cover.
I have found several clutches and parts in eBay but all are 5 bolt. Do I need to look for a clutch from a different motor? 430???
Would it be better to go back to a 5bolt and get a clutch hub to hub? Will 5 bolt fit my basket?
Thanks!

Water pump seals and circlip came. Now just waiting for jug and piston. They should be here today!

post pic of your primary shaft and ill tell you what to do. 5 spring clutch can be used with correct crank gear