83 CR500, here begineth the lesson

[Wildebeest90210]

Still waiting to hear about new ignition. How come I have chase up a small business to try to give them money!
Spent the afternoon on the mill today and mocked up the fork brace for finishing. Undecided as to polish or anodise gold, decision decisions!
Got to mod the mudguard again to hang from the underside.
I took a lump out of the kickstart stop to give just a little more swing and started finishing off the chain guide.

 

[86 400 XC]

Nice fork brace! All your fab is killer

 

[Wildebeest90210]

Nice fork brace! All your fab is killer

Cheers, takes me ages cos I'm not a proper machinist, I just jump on when its quiet. I will get some satisfaction from owning the only '83 Husky fork brace in the world though !

 

[SA63]

I have had very good prompt service from HPI (horsepower ignitions) in Belguim which seems to be the same equipment as electrex, but cheaper...
Electrex never replied to my emails...
I even got a blank rotor off them and machined it to suit the crank I was using.

 

[Wildebeest90210]

I have had very good prompt service from HPI (horsepower ignitions) in Belguim which seems to be the same equipment as electrex, but cheaper...
Electrex never replied to my emails...
I even got a blank rotor off them and machined it to suit the crank I was using.

Thanks. Electrex never returned my calls and the intermediary hasn't called back either so have no problem looking elsewhere. I take it HPI can be found on the interweb or do I have to get the train to Brugge and help drain the EU lager lake?

 

[dukkman]

Wilde I rekon that my setup will work on your bike .
You have enough voltage to spark sometimes so you have enough to work with this setup.
The other thing is that it costs less than $30 so you can chuck it without too many tears.
Parts required

On my 240 just to prove that I'me not crapping on and I have exactly the same deal on my 400 and as you can see it's been there a while.

 

[Wildebeest90210]

Thanks for that Mike. I just checked your last post. I give these people one last chance tomorrow, they got my flywheel still anyway and then try your method if they can't/won't help . With advice though if you don't mind as I am a proper electrical dunce !

 

[SA63]

a lager frenzy might be in order.. they are on the web though:
www.hpi.be/
I bought a couple of maico ignitions and a universal 4 stroke ignition , all less than $200 A, for the stator , rotor CDI and coil. info on ignition advance curves for 2 and 4 stroke on their website,
I got mine to replace points ignitions and have been pretty happy so far, but im not sure what they offer for hva, but you can buy a blank and machine it to suit.
willy is the guy, his english is so so but waay better than my flemish....

then agian the pit bike option is pretty cheap!

 

[dukkman]

The hardest part of this is finding a plug to fit .

I was going back trying to find a wiring diag and realized that my setup is for a SEM.
Don't know how it would work on a Motoprat.

 

[Wildebeest90210]

This looks very tidy. I will be very interested to see its final price. Guess this would be a 430 in a 500 frame like mine? I'm sure someone told be 83 was 500's only for CRs?

http://www.ebay.co.uk/itm/HUSQVARNA...6779129?pt=UK_Motorcycles&hash=item2576320379

 

[Wildebeest90210]

Just Ebayed these for next to nothing

 

[Wildebeest90210]

Well, pic 1;
Went to pick up ignition today from a very helpful third party. Its from electrex but turns out to be HPI gear as SA63 said.
Looks excellent, may have paid a little over the odds but saved money on a beer drenched trip to Belgium and made a really good Husky contact.

Next pics must be damage from kicking back and maybe I need to adjust the kick mechanism a little. The swarf is shattered off by impact, had some big ones.
I took the case off to fit a breather as its a 4T case as a small hole in the filler cap aint good enough. Lucky I did as the kickstart still works well, would never have known.

 

[Wildebeest90210]

New stand, not 6 sided on purpose, just what I had.


3/8bsp air fitting for a breather in the 4T case


What happens if you get the bushing slightly out when repairing crank cases for kickstart. Ouch. Knackered the gear as well so that will be bronze bushed to replace the needle roller and drilled to get some oil to it. Al
l this and its not even run yet !!


The new HPI kit is going on today..


And I hatch a plan to use the force to tame the rebel spagetti forks

 

[suprize]

i bet after the next kickstart session you will sound like a strangled Darth Vader as well!

 

[wrx]

Wilde, that kicker gear thing is a common problem. my 85 cr250's center cases got damaged behind the gear. bearing cage came apart and went through trans . NOT A PRETTY SIGHT.

 

[Wildebeest90210]

Wilde, that kicker gear thing is a common problem. my 85 cr250's center cases got damaged behind the gear. bearing cage came apart and went through trans . NOT A PRETTY SIGHT.

Lucky I looked before I ran it. I was only fixing an oil leak while I waited for the new ignition. I've made up an ally bronze bush and just sent the gear off to get some holes spark eroded to feed some oil to the bush. I hope that will be an end to it. Seems you don't have to have too much wrong to trash the needle roller and then, as you say the whole gear box can get the good news !!

 

[speedyauto]

Well, pic 1;
Went to pick up ignition today from a very helpful third party. Its from electrex but turns out to be HPI gear as SA63 said.
Looks excellent, may have paid a little over the odds but saved money on a beer drenched trip to Belgium and made a really good Husky contact.
View attachment 19806
Next pics must be damage from kicking back and maybe I need to adjust the kick mechanism a little. The swarf is shattered off by impact, had some big ones.
I took the case off to fit a breather as its a 4T case as a small hole in the filler cap aint good enough. Lucky I did as the kickstart still works well, would never have known.
View attachment 19807 View attachment 19808

That broken kickstart pawl & deformed gear is exactly what I had after really bad kick back problems on my 500 due to a shitty ignition,
I stuck the 1 from my auto in it but haven't quite got my timing right yet as I'm still getting a little kick back but it's ridable when I bump start it.
The auto ignition is a mini 6 & makes it really easy to start.
When mine kicked back it also broke a tooth off the back of the clucth basket so it might pay to have a look at that. Also if your bearing at the back of the cluth is the plastic cage job chuck it out & get the metal framed bearing as I've been told by a very knowlegable man that the plastic cage warps when hot & causes the drum to move & wear the clutch gear rapidly at strange angles (as mine was & now has a metal frame bearing & new clutch drum).

 

[Wildebeest90210]

Timed in the new HPI 2.2mm BTDC. Got a horrible feeling on the bench I did 2.2 AfterTDC before !!??? Still new gear looks the biz and when I get the kick gear back its a return to the one kick strategy! Have witnessed a 3 kick with this ignition from the guy who sorted me out with it. Put an m6 stop on the bracket and taped up the primary drive to tighten the new flywheel without the woodruff key. Looks bang on.






And a new breather on the 4T case

 

[Wildebeest90210]

Still waiting for the kickstart gear to come back with oilways added so I can fit the ally bronze bush. Mean while been working on chain guide.
Bearings on the rollers kept nipping up then I worked out they are like miniature wheel bearings so made some spacers to go between the bearings to tighten up on just like the tubes inbetween proper wheel bearings.
In pic 2 got it mocked /tacked up for measuring tonight. Depending on wine consumption that is, might do it in the morning.

 

[suprize]

Wine consumption eh? getting cold over there again? we have just finished the last bottle of red nd are tasting whites for a looonnng hot summer. corona's nd 4xxx in the fridge! 1 last vinduro in a months time and ive stripped the lower clutch case bolt! bu%^er