Hustler 980 tall tub build

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Thread: Hustler 980 tall tub build

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  1. #1
    Join Date
    Feb 2016
    Location
    Mississippi
    Posts
    1,108

    Hustler 980 tall tub build

    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

    20190512_180557.jpg20190512_180616.jpg20190512_180738.jpg

    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.

  2. #2
    Join Date
    Dec 2008
    Location
    Eastern PA
    Posts
    262
    Congratulations on the purchase. I will be anxious to follow the rebuild.

  3. #3
    Join Date
    Jun 2007
    Location
    Northern VA
    Posts
    2,766
    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!
    Stuck in the seventies- not in the swamp.

    (6) Attex, a Hustler, a Super Swamp Fox, (2) Tricarts, (3) Tri-sports, a Sno-co trike, 3 Dunecycles, and a Starcraft! ...so far

  4. #4
    Join Date
    Feb 2016
    Location
    Mississippi
    Posts
    1,108
    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:
    20190514_071909[1].jpg

    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:
    20190514_071747[1].jpg

    Of course, none of this puts the 980 any closer to being on the trails....

  5. #5
    Join Date
    May 2009
    Location
    NJ 08533
    Posts
    5,055
    Any difference in the 950?


    My new beer holder spilled some on the trails - in it's hair and down it's throat.
    Joe Camel never does that.

    Advice is free, it's the application that costs.

  6. #6
    Join Date
    Feb 2016
    Location
    Mississippi
    Posts
    1,108
    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.

  7. #7
    Join Date
    Jul 2011
    Location
    Garner, NC
    Posts
    865
    Looking really nice,,,, and my hats off for the Split shift engineering!!
    HUSTLEMANIAC and a HONORARY MEMBER of the
    BIGFOOT ALUMNI

  8. #8
    Join Date
    Feb 2016
    Location
    Mississippi
    Posts
    1,108
    Thanks guys. I'm building the transmission now.

  9. #9
    Join Date
    Feb 2016
    Location
    Mississippi
    Posts
    1,108
    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.

    20190731_070140[1].jpg

  10. #10
    Join Date
    Feb 2016
    Location
    Mississippi
    Posts
    1,108
    Made a little progress this weekend. Worn holes in the T20 mount were repaired by welding them up and drilling/cutting new ones.
    20190804_134307[1].jpg20190804_135944[1].jpg20190805_064001[1].jpg

    I'm going to replace the outer frame rails. They've got some heavy rust damage and lots of twists and turns.

    20190805_064031[1].jpg20190805_063818[1].jpg

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