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Author Topic: KX 80 Rebuild/rebirth  (Read 8289 times)

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Offline adzski

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KX 80 Rebuild/rebirth
« on: June 25, 2013, 02:19:33 PM »
hey everyone.

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
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline adzski

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KX 80 Rebuild/rebirth
« Reply #1 on: June 25, 2013, 02:21:33 PM »
oh forgot to mention it already had some goodies.

Full Pro circuit exhaust
rear renthal sprocket
and brand new back tire
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline adzski

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KX 80 Rebuild/rebirth
« Reply #2 on: June 25, 2013, 02:37:49 PM »
how she sits Currently


cleaning the cases




soaking some internals in kerosene (shift drum,shift forks)


will update as things happen


« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline TMKIWI

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KX 80 Rebuild/rebirth
« Reply #3 on: June 26, 2013, 06:52:40 AM »
Looking good mate.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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If you don't fall off you are not going hard enough

Offline adzski

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KX 80 Rebuild/rebirth
« Reply #4 on: June 26, 2013, 11:03:47 AM »
thanks pal, i quiet liked your rm vmx builds also  :D
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline eprovenzano

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KX 80 Rebuild/rebirth
« Reply #5 on: June 26, 2013, 01:36:33 PM »
fun project  and yes the fenders need replaced
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Eric Provenzano
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Sold 1974 Honda Elsinore CR125

Offline adzski

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KX 80 Rebuild/rebirth
« Reply #6 on: July 04, 2013, 09:37:18 AM »
PROBLEM HELP.

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
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline SachsGS

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« Reply #7 on: July 04, 2013, 02:11:08 PM »
Crankshaft o.k.?
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Stusmoke

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KX 80 Rebuild/rebirth
« Reply #8 on: July 04, 2013, 11:16:56 PM »
Quote from: SachsGS on July 04, 2013, 09:11:08 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.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline adzski

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« Reply #9 on: July 05, 2013, 01:55:21 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.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Stusmoke

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« Reply #10 on: July 05, 2013, 05:30:14 AM »
Quote from: adzski on July 05, 2013, 08:55:21 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?
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline adzski

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« Reply #11 on: July 14, 2013, 03:31:25 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
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Stusmoke

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« Reply #12 on: July 14, 2013, 05:18:23 AM »
Quote from: adzski on July 14, 2013, 10:31:25 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 :P
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline adzski

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« Reply #13 on: July 14, 2013, 05:59:02 AM »
hahah yeh well fair to say id be doing the same from now on! ;)
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline adzski

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KX 80 Rebuild/rebirth
« Reply #14 on: July 14, 2013, 06:54:06 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


« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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