Project is finally finished! Grips and hand guards are in place and running problems was caused loose cylinder head bolts. I didn’t tight them enough so engine was taking air from head gasket..
Carb needs a bit adjusting and new gasket. Rear sprocket needs to be replaced also. But I’m pleased with the result and test drive was successful!
Today we almost finished the bike. Basically only thing left is new grips and hand guards. Carb, heat shield, plastics, rear brake, new tires and hour meter was assembled today. And we also started it first time. It was revving much quicker than before, but it ran better with choke on so it seems that it’s not getting enough gasoline. Not even we replaced stock 15mm carburator with 21mm DellOrto. It needs more gasoline cause ported cylinder and better flowing exhaust. Need to buy few larger jets for the carb. Hopefully I can test run it tomorrow 🙂
Still things to do but bike starts looking like a bike again 🙂
I cleaned the plastics under the shower using 600 and 800 grit wet sandpaper. They are not perfect but pretty good for 23 years old. New stickers are also waiting. Here is few before / after pictures..
Today we finally made some progress. Well perhaps I shouldn’t say we, my friend mostly. He finished exhaust and rear shock extender and made new spacers for rear wheel. Chains are in line now.
What still needs to be done? Fix the heat shield, install the carburator, clean the plastics and put new stickers on, install break and gear pedals, front brake, throttle and change the tires. And much more what I don’t remember 🙂
Project is slowing down. Other things and work has kept me busy.
Anyway, assembled wheels, new brakes, chains and chain guide.
Chain line is off maybe a 5mm and I’m still thinking should I do something about it. I think it’s because rear wheel hub isn’t original. Wheel would line up if I made new spacers. I’m just not sure if 5mm is that big of a deal..
Exhaust is still waiting finishing. One of the heat shields fasteners needs to be welded back, all the welds need to be grinded smooth and it needs to be painted. Rear shock extender is also unfinished.
But it will get done eventually. Though my son started to ask when he is going to get the bike back..
It’s been slow week with the project but I cleaned and painted the wheels, fixed wiring and continued fixing exhaust. Rear shock and exhaust needs still modification but everything else is just waiting assembly.
Didn’t get too much done today, but I did make cover for removed oil pump from carbon fiber. Yes, real carbon fiber! I don’t think that many people have carbon fibre parts in their PW80 🙂 Also installed electronics back to frame, painted the rear shock and spring and fitted the handlebar. Of course I had wrong size nuts for it.. Exhaust was test fitted. It needs a bit modifications because silencer isn’t original and somebody has modified end of the exhaust. I don’t have a clue how to modify exhaust but luckily my friends will help on that. I also changed exhaust’s normal M8 bolts to studs.
Cylinder and cylinder head was next on the list. Unfortunately I didn’t take before and after pictures from the cylinder. My friend modified cylinder ports a bit and it looked pretty nice. Can’t wait to see how it runs.
I changed oils and oil seals for front shocks few months ago so I just cleaned and painted them before install. Old footrest was bended and welded poorly so I ordered new original with kickstarter, side stand and few other parts from Yamaha. Foot pegs I ordered earlier from Ebay.
Then the kickstarter. It was working fine when I tested it without clutch cover. But with cover, spring didn’t return and kickstarter was left down. So I took off the cover and of course ruined the seal. I installed the starter shaft few times and it didn’t return properly. Finally I figured out how to twist spring so that there was enough tension and starter returned also with cover on..
Engine found its place. No big issues here. Just had to be careful not to scratch new paint.
Only thing was that I forgot to put flywheel in place before cover.. And I did it twice! You shouldn’t work tired..
Yamaha PW80 1992 