Post by: adzski on June 25, 2013, 02:19:33 PM
well a while back now i bought a hacked out kx80 2000 for the misses to ride, so i can take her when i go away on weekend trips, cost me $300 AUD
when i bought the bike lets just stay its seen better days and if it were a person would of jumped into my arms.
everything was in bits and pieces and everything that was fixed was half ass'd and just not done properly .
so far i have torn the motor down and replaced
.shift drum bearing
.crank bearing
.outer and inner clutch basket (i broke them prior though)
.Cleaned out the Carb
. Had to buy reeds and intake boot
. new brake pads
as for rebuilds
. complete new top end, sadly used a namura piston ( i didnt no
). rebuilt the swing arm (bearing seals)
Cosmetics
. didnt come with a seat, now has one
. new pink grips
. painted her leavers pink ( wasnt the best idea)
. i tried to paint the shifter,brake,kickstart used engine enamel but comes off to easy will get powder coated later on
. yet to buy new fenders
. yet to buy new side panel was missing one
things yet to buy
.kill switch
.ordered clutch cable just waiting for arrival
Problems, having some issues with the outer clutch case, it wont sit flush with the case, looks like the part that pushes on the shift shaft to put pressure on it so nothing pops out makes it sit to high and, wont sit flat ( curently at local bike mechanic)
will throw on some pictures up soon
Post by: adzski on June 25, 2013, 02:21:33 PM
Full Pro circuit exhaust
rear renthal sprocket
and brand new back tire
Post by: adzski on June 25, 2013, 02:37:49 PM
cleaning the cases
soaking some internals in kerosene (shift drum,shift forks)
will update as things happen
Post by: TMKIWI on June 26, 2013, 06:52:40 AM
Post by: adzski on June 26, 2013, 11:03:47 AM
Post by: eprovenzano on June 26, 2013, 01:36:33 PM
Post by: adzski on July 04, 2013, 09:37:18 AM
ok today finished the bike off and started it, and noticed as strange noise perhaps piston knock? anyway ran it a few more times, then went to ride it but it stalled. then wouldnt start. and then i kickstart would go down, but i persuaded it with a mallet and then it went down but still happens. any ideas?
brand new piston in there
Post by: SachsGS on July 04, 2013, 02:11:08 PM
Post by: Stusmoke on July 04, 2013, 11:16:56 PM
Crankshaft o.k.?
x2. If you ever have a lock up of the kick starter don't try forcing it. If its your crank you will make it worse and possibly damage other parts if you get it to run again. Pull Cylinder off and try moving the piston up and down. If that works then check that your piston didn't catch on teh exhaust port.
Post by: adzski on July 05, 2013, 01:55:21 AM
my concerns
as i didnt get the cylinder re-sleeved, i just honed it myself , and didnt feel like much compression? but im use to my 250.
also the crank looked ok when i split the cases but ill see what he diagnoses it.
Post by: Stusmoke on July 05, 2013, 05:30:14 AM
hmmm, ok well today im taking it to a local mechanic to diagnose then ill fix it myself.
my concerns
as i didnt get the cylinder re-sleeved, i just honed it myself , and didnt feel like much compression? but im use to my 250.
also the crank looked ok when i split the cases but ill see what he diagnoses it.
If you're confident of your honing work then I would attribute the fact it feels like it has little compression to the fact you're used to a 250. Even 125s feel like nothing compared. Did you check your big end clearances when you were doing the top end? Checked main bearings?
Post by: adzski on July 14, 2013, 03:31:25 AM
problem was that i thought i lost the nut for the flywheel, but as its magnetic i didnt see that it was in the back of it.
it tore the stator to shreds.
2nd problem was the bore, it was actuallly larger than i thought and i put a kx80 piston in when the bore was a kx85 i never checked (amateur mistake).
so going to needs a new piston and stator $300 fix so nothing to crazy.
ill measure the bore and see if its been bored out. the standard i believe is 48.50mm
Post by: Stusmoke on July 14, 2013, 05:18:23 AM
ok good and bad news.
problem was that i thought i lost the nut for the flywheel, but as its magnetic i didnt see that it was in the back of it.
it tore the stator to shreds.
2nd problem was the bore, it was actuallly larger than i thought and i put a kx80 piston in when the bore was a kx85 i never checked (amateur mistake).
so going to needs a new piston and stator $300 fix so nothing to crazy.
ill measure the bore and see if its been bored out. the standard i believe is 48.50mm
Mistakes happen. The first one is one that I can guarantee I would have made too. As for the second, I always measure my bore like 10 times and compare it to OEM standards before choosing piston size. And thats if I'm feeling relatively non paranoid
Post by: adzski on July 14, 2013, 05:59:02 AM
Post by: adzski on July 14, 2013, 06:54:06 AM
went to local shop and got the jug and old piston measured.
he mentioned it may have orignally been 48.48 would have worn 48.50mm.
so i found this
http://www.ebay.com.au/itm/Wiseco-48-50-MM-Pro-Lite-Piston-fits-Kawasaki-KX-80-88-00-644M04850-/350832166942?pt=Motorcycles_Parts_Accessories&hash=item51af3a081e
Post by: Stusmoke on July 14, 2013, 08:16:47 AM
need help pikcing a piston.
went to local shop and got the jug and old piston measured.
he mentioned it may have orignally been 48.48 would have worn 48.50mm.
so i found this
http://www.ebay.com.au/itm/Wiseco-48-50-MM-Pro-Lite-Piston-fits-Kawasaki-KX-80-88-00-644M04850-/350832166942?pt=Motorcycles_Parts_Accessories&hash=item51af3a081e
How big was your cylinder? Remember that a cylinder that is 48.50 mm won't take a piston that is also exactly 48.5 mm. Judging by the .au part of the link i guess you're in Aus? If so, I would point you in the direction of: http://www.motocrossparts.co.nz/
Good stuff, good prices, good people. Those guys sell wossner pistons and the one I've put in my CR is ripper. Holds up well to my abuse and its good enough for Dungey, Roczen and Marv (I think Wossner supports the KTM factory teams anyway). If you're wondering about piston sizes, give them a bell and they're happy to help you out. And you get to giggle if you have lots of sevens in your credit card and ask them to read it back
Post by: adzski on July 15, 2013, 01:06:24 AM
and the guy said the barrel was worn, so it would be bigger than 48.50?
im going to take it to another shop and get it measured again to be 100%
Post by: Stusmoke on July 15, 2013, 04:16:10 AM
well it would have to be 48.50
and the guy said the barrel was worn, so it would be bigger than 48.50?
im going to take it to another shop and get it measured again to be 100%
Did the shop measure your cylinders bore? What was it?
Post by: adzski on July 15, 2013, 07:57:00 AM
yeh they both measured it and its larger than 48.5, id say it would be around 49 or slightly over cant exactly remember what he said but i made sure that it was over 48.5 anf there was enough room for ring gap.
that should be coming either tomorrow or the following day, so all i need now is the stator.
Post by: Stusmoke on July 15, 2013, 08:34:31 AM
Post by: adzski on July 15, 2013, 01:35:58 PM
so to clarify the bore size should be 48.9? or?
Post by: Stusmoke on July 15, 2013, 10:44:07 PM
http://wossneronline.com/forged_pistons/index.php?main_page=product_info&cPath=50_64_97&products_id=833
Theres all the piston sizes available for your bike. If you have to you can order directly off them, or visit http://www.motocrossparts.co.nz/ ring them up and see if they can't get you one.
I would get an accurate reading of how big your cylinder bore is. Actually I would go one step further and buy a Cbore gauge and do it myself to be certain. Then you can order in an appropriately sized piston.
Post by: adzski on July 16, 2013, 10:11:02 AM
should be ok he has advised me with my bike and serviced it before and always done a good job.
Post by: adzski on July 17, 2013, 10:27:32 AM
so ive been a busy boy.
got the piston and gaskets today, everything fit perfect as the shop said it would, so now the top end is together and the motor is bolted into the frame, connected all the hoses to radiator, re-attached clutch cable, and just a bunch of little things.
all thats left to do is
.bleed the rear brakes
.put new stator on (picking up tomorrow)
.get radiator fluid, and new plug.
then start it
will takes pics tomorrow, took some today but will upload tomorrow.
Post by: Stusmoke on July 17, 2013, 10:43:53 AM
Post by: adzski on July 17, 2013, 12:39:26 PM
Post by: Stusmoke on July 17, 2013, 09:31:03 PM
it was pretty tight my mechanic told me to put the piston in from the top and watch it slid down slowly and if it drops its to small and it slid down slowly, but felt the same as when i did my 250s piston, and as for the ring its only running one ring instead of two like the 2014 kx85.
Sounds like everything is good there, that is a good little trick aswell. Make SURE You put the piston in the right way! Single ring pistons are good, but you need to change rings a little more often.
Post by: adzski on July 19, 2013, 12:48:14 AM
Post by: adzski on July 20, 2013, 04:04:50 AM
It kinda comes on late, and only really felt it in 1st and 2nd.
I'm thinking a pv problem or maybe the carb needs adjusting.
I'm gonna get another plug and see if that helps.
Post by: Stusmoke on July 20, 2013, 04:24:23 AM