• Husqvarna Motorcycles Made In Sweden - About 1988 and older

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    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

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1987 XC430 to 500 conversion

A

Artic Dog

Husqvarna
Hi all,
Is it possible to convert a 430 into a 500, if so what parts do i need? any help would be amazing regards,
Dog
 
the pistons are quite different, they only share a ring as they are the same bore, different height different skirt and different wristpin, I have both and when I get a chance I will take a picture
that said,, the crankshaft assembly, the cylinder and head, and a pipe, studs are the same but the nuts and bolts are different
 
It wouldn't hurt to have a few spare engines as one never knows what will be found in the process. The crank of which there were three variants of in the water cooled version 500 over the 85-87 time frame. Probably the middle version would be the preferred one. Or maybe a later version not really familiar with what was created besides the new stuff posted on here lately.

The piston is longer and has a larger wristpin, a 500 cylinder and head to go with it. The studs are actually the same it is the head nuts on the studs that accommodate the 10mm longer stroke and the head gasket has larger holes because those nuts go down that far.

If I recall correctly by 87 the xc 500 uses the same reed cage to carb rubber not the lager one for the 40mm. If you do use the 40 mm carb then the carb to air box rubber.

The primary reduction gearing for that 87-88 bolt on six spring clutch in 500 ratio is probably pretty close to unobtainable. Either deal with the primary gearing you have which might spin the engine a bit fast to be able to kick it through or change out the transmission parts to the earlier clutch and 39/70 primary. More of an opinion not a need type of thing. Of course the exhaust pipe will have a different part number but some of the aftermarket pipes are labeled for either. You can go through the parts sheets and see for yourself I think I noted a few things that aren't obvious doing that. I may well have missed something.

Fran
 
Fran
good point on the primary gearing I forgot that part, interesting was the 5 spring vs 6 spring clutches, they did not just add a spring
the 5 spring clutch was smaller and had less inertia weight to affect the handling, but the downside was a fairly heavy clutch lever pull
in 87 they dramatically increased the diameter of the friction surface and installed lighter springs, they also removed the snap-ring mounting method and added a nut to the end of a new main shaft, the reason to use the nut was preload setup at new was fine but as time goes on play and a possible snap-ring failure caused a rethink of designs
 
2premo said:
Fran
good point on the primary gearing I forgot that part, interesting was the 5 spring vs 6 spring clutches, they did not just add a spring
the 5 spring clutch was smaller and had less inertia weight to affect the handling, but the downside was a fairly heavy clutch lever pull
in 87 they dramatically increased the diameter of the friction surface and installed lighter springs, they also removed the snap-ring mounting method and added a nut to the end of a new main shaft, the reason to use the nut was preload setup at new was fine but as time goes on play and a possible snap-ring failure caused a rethink of designs
Click to expand...

The real downside the way I see it is that the "half round" that pushes the clutch rod just rides in the magnesium case (two cycle here) the added stress there makes for more wear as by now bikes with clutch cables have bearings there.

The 70 tooth clutch gear just won't fit with those larger clutch plates. There was a thread on here a but more than a month ago with a guy in Africa looking for one of those gears. It has what must be the minimum number of teeth perhaps 72 a bit of errors in the tech data as I recall. I researched the parts sheets and even tried to buy a gear for my 87-88 430 which Halls shows available but it really isn't. The 87-88 whole clutch basket is steel intresting that the majority of the ktm line hence 2014 austrian husky most likely have that as well dds with a diaprham spring and damping which I have to go back to my 360 1976 to find.
 
Awesome reply guys, this conversion seems to be quite elaborate, i was hoping it might have been a case of just swapping the crank, carb and cylinder......:rolleyes: perhaps I'll have to look out for a 500 engine, do all the water cooled 500's share the same engine mounts?
Regards,
Dog.
 
....another good lesson of SweedishTecnicque from 2premo....:cheers:********************************************************************************
Thanks alot again !!!
 
Artic Dog said:
Awesome reply guys, this conversion seems to be quite elaborate, i was hoping it might have been a case of just swapping the crank, carb and cylinder......:rolleyes: perhaps I'll have to look out for a 500 engine, do all the water cooled 500's share the same engine mounts?
Regards,
Dog.
Click to expand...

they are interchangeable same mounts etc. the only real difference is the clutch and the trans shaft it goes on
if you just want to scare yourself they will all do if you actually plan to ride it the larger external flywheel takes a bit of the jerkiness out of it and gives you a light circuit, but the CR internal rotor is more reliable, I suppose you could add weight to make up, but stock is stock
 
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