Hustler 980 tall tub build

[dirtdobber]

Some 18 months ago I was able to buy a 980 tall tub machine. It was a running machine when I bought it but I knew some things weren't just right with it. Finally, I'm getting around to working on it. I'm going to pull it completely apart and rebuild it so I know what I have.

Pulled the top off a few weeks ago and today pulled the engine. So far, the rubber engine mounts weren't compressing and holding things tight, allowing the engine to rock back and forth. The T20 is only half way mounted and its actually loose in the cradle. The plungers seem a little far out of the case. I'll probably open it up just to take a look.

Here's a few pics

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I'm going to take the 18 horse from this machine and drop it in my 950. The 950 has a 20 horse but I don't believe it is running as strong as it should. I just want to see if there is any noticeable difference.

As for the 980, I have a 22 horse Yanmar diesel to go in it.

This is going to be a slow moving thread.

[onlyonce]

Congratulations on the purchase. I will be anxious to follow the rebuild.

[Don]

That sounds like a fun project. The BFD works great with a Kubota diesel and if I remember rightly, it's only rated at 19 or so HP. It doesn't go fast, but it has lots of grunt power. Good Luck!

[dirtdobber]

Did a little work on the 18 horse prepping it to go into the 950, and made a goof. On the 980, the exhaust system has a reducer that screws into the head. Those have to come out to accept the exhaust setup on my 950. One came out easily, the other was a real pain.

I wound up having to cut the adapter and weld something to it to get a bite with a pipe wrench. 20190514_071840[1].jpg
With an 18 inch pipe wrench and a 24 inch cheater pipe and a lot of grunting, it finally moved.

I then realized the engine would not turn a full revolution after I removed the exhaust adapter. A little BB size of metal from the welder made its way into the combustion chamber. So that goof cost me a head gasket, but I was pleased to see the condition of the cylinder:
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Finally, I have a problem with my choke cable. As I ride it vibrates into the choked position, so I have to bump it back open every once in a while. I fashioned a little spring to solve that problem:
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Of course, none of this puts the 980 any closer to being on the trails....

[ARGOJIM]

Any difference in the 950?

[dirtdobber]

Any difference in the 950?

I finally got to give it a test drive today and it does feel a little stronger. It has taken some time to make the swap because I got rid of the governor and had to fab throttle linkage. On the maiden voyage several days ago it died after about 50 yards - carb was dirty even though it is new (been sitting a while). I'm in the process of swapping the starter as the drive gear on the 18 horse is about shot. Then, I've got to do something with the carb. The new carb is slightly different from the original in that the fuel pump mounts about 1/4 inch higher on the body. This keeps the air cleaner housing from seating correctly.

[fmints]

Looking really nice,,,, and my hats off for the Split shift engineering!!

[dirtdobber]

Thanks guys. I'm building the transmission now.

[dirtdobber]

T20 is ready to go. Relined bands, new seals, one new bearing and one new thrust washer. The thing is, though, the plungers are going to stick out of the case rather than being inset. Drums are in great shape, but I guess they could have been turned at some point.

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[dirtdobber]

Made a little progress this weekend. Worn holes in the T20 mount were repaired by welding them up and drilling/cutting new ones.
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I'm going to replace the outer frame rails. They've got some heavy rust damage and lots of twists and turns.

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