What happens to race bikes when they retire? Sometimes they end up sitting in the corner of a garage, but more often than not, they become a headache for unsuspecting buyers. This TC85 was one such case. After being raced for a season by the original owner, it was cleaned up and sold. The new owner took it on a few desert trips before the engine gave up. After a couple unsuccessful attempts at rebuilding it, we rescued it from a Marketplace ad. To bring our 2019 Husqvarna TC85 back to life, we enlisted the help of “Project Bike Master” Jay Clark.
Decal Works gave the bike a classic yet updated look with a semi-custom graphics kit, and we mounted them on a complete set of all-white plastics from MXPlastics.com. We partnered with various companies during the rebuild, including Decal Works, Motoseat, Rekluse, Nacstar Wheels, ProX, Wiseco, FMF, Dunlop, Lectron, Works Connection, UFO Plastics, San Diego Powder Coating, Schmidt Performance, ODI, Sano Metal Finishing, Cranks By Andrew Langston, and ParaPros. As part of the rebuild, we decided to upgrade to larger wheels, transforming it into a Supermini project by using a complete set of blacked-out Nacstar wheels and ProX components. Schmidt Performance set up the suspension to accommodate the larger big-wheel size.
PROJECT TC85
When we first came across this Husqvarna TC85 on Marketplace, we thought, “Oh no, someone is going to buy that bike and be very disappointed!” Then we had the idea of turning it into a project ourselves to save someone from that headache. Okay, maybe we have some issues, but the seller was honest with us about the bike’s problems, so we already had a game plan in mind. We just needed to execute it. For that, we enlisted the help of bike builder Jay Clark and his network of leading companies in the moto industry. We then stepped back and watched the magic happen.
The main problem with the bike was the engine. Despite being rebuilt after its racing retirement, it would not stay running for long. Brad at ParaPros Racing, who is skilled at solving engine issues, took on the challenge. After a complete teardown and cleaning, they found a few air leaks, as well as some problematic gas and a lean oil/gas mixture.
The crank was rebuilt using a ProX rod kit from Langston Motorsports, and it was put back together with all-new bearings, seals, a top-end kit, and gaskets from various aftermarket products. To give the bike some additional power, a Rekluse Core manual clutch system, VForce reed intake, and a complete FMF exhaust system were added. The final aftermarket touch was the brand-new Mini Billetron carburetor from Lectron.
While Brad worked on the engine, Jay Clark addressed the chassis issues. The first step was to send the main frame to Chris Johnson and his team at San Diego Powder Coating to give it a fresh satin black finish, replacing the faded blue color. Similarly, Sano Metal Finishing vapor-blasted the triple clamps, swingarm, and braking systems to make them look better than new. All the chassis bearings were replaced using ProX kits, and the suspension received major attention from Schmidt Performance to prepare it for off-road Grand Prix-style events. The stock wheels were upgraded in both style and size using a set of NacStar wheels, complemented by Dunlop tires, a ProX sprocket, and ProX brake rotors.
This project had a unique aspect compared to most Marketplace builds we undertake—we had a lot of information about the bike’s history. This greatly reduced the guesswork involved and, in some ways, the fun factor, but we certainly did not miss the surprise headache moments. Jay Clark successfully completed the complete rebuild and upgrade to Supermini status with the addition of the Nacstar 19-/17-inch wheel combo, while Brad at ParaPros handled the engine work without any issues. We are pleased to report that this project is already winning races in the Supermini division at the NGPC and SRA Grand Prix series. Once again, another happy ending!