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Father/Son PW80 Restoration


crane550

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Hello,

Greetings from Boise, Idaho. Very first post here at TT, although I have lurked for a while. Just wanted to share our story, and possibly ask some questions as we go. I have a DRZ400, and my son has my '86 Honda Z50R that I rode when I was a kid. Haven't ridden for a while, but figured we should get back into it and spend some father/son time together.

He is 10, and pretty new to riding. We did go on an adventure up in the hills and had a great time. He took a couple spills, but got right back up. Even though he is pretty new, I got the feeling that the bike was holding him back a bit. So I hit up Craigslist and found something advertised at a "1986 PW 60". To be completely honest I had absolutely no knowledge of the PW platform. The guy seemed anxious to sell it, so $500 took it home. After doing some research I found there is no such thing as a "PW 60", and it was most likely a PW 80. A bit more reading, and I knew for sure what it was. Ran the VIN number at the dealer, and found out it's a 1996.

We plan to fix it up and head into the hills. Stay tuned for updates.

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3 minutes ago, S.O.A.N.Z said:

you sure its not a 50

cc's will be on the cylinder

Positive. The 50's are shaft driven, plus the dealer looked up the VIN. And to remove all doubt you can also see this.

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Definitely a Pw80, the 50 has no shifter. If it runs well that's a good deal, parts are plentiful n not too expensive. They're basically indestructible n will run forever. I've had 3 or 4 of them when my kids were growing up n the first thing I always did was to buy metal toothed foot begs n threw the rubber ones out... rubber ones are super slippery n actually dangerous imo. Get a seat cover, plastics if u care, clean 'er up n have a blast... excellent starting bike for  10 year old! 

Edited by delawhere
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Got it and took inventory. Doesn't run very well, but when it does it sounds solid. Has to be a carb issue. Also seems to shift clunkily, especially from 1st to 2nd. It might be the idle adjustment.

Teardown begins. It was crazy dirty, and built up with years of oil and grime. We took off the plastics and threw them aside, and then started alternating between heavy spray downs on industrial degreaser and power washing. Was impressed with how well it actually cleaned up.

Pretty much kept disassembling until there wasn't anything left to take apart any more. Pretty much the only thing we didn't do was split the case, as I don't see a reason to do that at this point.

Stay tuned.

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9 hours ago, S.O.A.N.Z said:

ok i must be going blind

Don't feel too bad. The seller didn't know, I didn't know, and there were other sellers on Craigslist who have bikes the look the same and don't seem to know. Guess it's not as easy when there aren't huge stickers on the sides telling you exactly what it is.

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Hey, these are great projects especially for a father and son.

I'm doing one with my boy at the moment too, we bought a bike with a seized big end.  I've got a new crank and barrel and piston ready to go on.

Our bike seized because one of the throttle cables snapped due to rust, it was the oil pump cable!

Just getting the bike back to a rolling frame, then I'll be splitting the cases.

Some good upgrades to do:

Upgrade the rear shock, cheap shocks available on ebay etc.

Add some preload spacers in the top of the front forks

Thicker fork oil and 6.5" air gap

Better pegs as someone else also mentioned

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28 minutes ago, Simon J said:

Hey, these are great projects especially for a father and son.

I'm doing one with my boy at the moment too, we bought a bike with a seized big end.  I've got a new crank and barrel and piston ready to go on.

Our bike seized because one of the throttle cables snapped due to rust, it was the oil pump cable!

Just getting the bike back to a rolling frame, then I'll be splitting the cases.

Some good upgrades to do:

Upgrade the rear shock, cheap shocks available on ebay etc.

Add some preload spacers in the top of the front forks

Thicker fork oil and 6.5" air gap

Better pegs as someone else also mentioned

 

I'm sure we are going to have some good notes to compare.

Can you tell me more about the spacers for preloading the front?

Alex

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When you remove the caps off the top of the forks, you can just add 1" spacers inside.

I used some small sections of pipe and then once you add the fresh thicker oil 15-20wt just screw the caps back on.

Makes them a bit stiffer

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5 hours ago, crane550 said:

Got it and took inventory. Doesn't run very well, but when it does it sounds solid. Has to be a carb issue. Also seems to shift clunkily, especially from 1st to 2nd. It might be the idle adjustment.

Teardown begins. It was crazy dirty, and built up with years of oil and grime. We took off the plastics and threw them aside, and then started alternating between heavy spray downs on industrial degreaser and power washing. Was impressed with how well it actually cleaned up.

Pretty much kept disassembling until there wasn't anything left to take apart any more. Pretty much the only thing we didn't do was split the case, as I don't see a reason to do that at this point.

Stay tuned.

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Looks a fun restore, thats what its all about

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Progress continues. Spent until the wee hours of the morning sand blasting and Cerakoting just about every part it would be applicable to. Cerakote is a bake on gun finish, and is super hard. Plus it looks good, and has great wear resistance. You do have to bake it on, which requires an oven. As much as I would have liked to do my frame in Cerakote, the oven isn't big enough. So I rattle canned it with Engine Enamel.

Gave the motor one last bath and got in and personal with the brush to get it squeaky clean. Not going to paint the motor. Gotta draw the line somewhere. But I am going to remove the head and cylinder so I can run a hone through it and check the piston.

Spend stay up all night making stuff pretty and you are an overnight success.

Lucked out on the front tire. It's brand spanking new. But I am going to redo the forks with new seals and fluid.

Just like that we are on to reassembly.

Okay, finally caught up to where we are now. No more pictures to show just yet, but stay tuned. We are scarfing down a home cooked meal, and will head back out to the shop momentarily to continue.

 

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Crane,

Please have your son read this post.

To Son of Crane,

You are experiencing a very special time with your dad. I suggest that you take lot's of pictures and remember as much as you can because it is the beginning of your time with motorcycles. Not everyone will have this chance to share a project like this as a son (or even a father!) so have a blast !

PS: Yes,you still have to clean the garage,feed the dog/cat/iguana and keep your grades up. We all did that too.

Blessings 

 

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Very cool, great job!  

I bet you've watched Aaron Colton on youtube rebuilding his PW50?  Lots of good tips on there.

I've got some Cerakote its an amazing product when done correctly, makes everything look awesome.

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2 hours ago, Wally_Tunison_in_N.J. said:

Crane,

Please have your son read this post.

To Son of Crane,

You are experiencing a very special time with your dad. I suggest that you take lot's of pictures and remember as much as you can because it is the beginning of your time with motorcycles. Not everyone will have this chance to share a project like this as a son (or even a father!) so have a blast !

PS: Yes,you still have to clean the garage,feed the dog/cat/iguana and keep your grades up. We all did that too.

Blessings 

 

Awesome post Wally...totally second that. It's fantastic to see the young fella getting involved in all these bits...he actually gets to learn how the bike works as he goes. Invaluable knowledge base!

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2 hours ago, Simon J said:

Very cool, great job!  

I bet you've watched Aaron Colton on youtube rebuilding his PW50?  Lots of good tips on there.

I've got some Cerakote its an amazing product when done correctly, makes everything look awesome.

Actually, I did see it part way into this project. I'm not sure if I was bummed or elated to see him also do Burnt Bronze on his motor covers. That was MY idea! LOL. But I do love his videos. I watched several of them while working this last week. Bright guy.

While we are on the subject, I also found this channel. No idea why I haven't heard of this guy before now. His videos are hilarious.

 

 

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2 hours ago, Wally_Tunison_in_N.J. said:

Crane,

Please have your son read this post.

To Son of Crane,

You are experiencing a very special time with your dad. I suggest that you take lot's of pictures and remember as much as you can because it is the beginning of your time with motorcycles. Not everyone will have this chance to share a project like this as a son (or even a father!) so have a blast !

PS: Yes,you still have to clean the garage,feed the dog/cat/iguana and keep your grades up. We all did that too.

Blessings 

 

I am 100% reading this to him! Thank you for the kind words.

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Progress continues. Wow, what a difference a couple of hours can do. Also the big brown truck came with gaskets, a rear tire, and fork seals. Couldn't do much without those, so it was the wait game. But with a shiny new cover and head gasket I could get the engine put back together.

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Didn't get many pictures, but I did get the forks put together. I didn't add the spacers yet for now since it would be very easy to add later. Thanks for the tip. Did the seals and new 15W fluid.

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Next up it was time for tires. I had a local shop (Revved Up Motorsports in Meridian) put the tire on the rim for $15, and they even agreed to do it by the end of day. Excellent shop.

The tire is cheap off of Amazon. $47.89, and it came with a tube. Figured it would be a good idea to keep the overall cost down, but give the kiddo some grip. Not sure about the brand which is Hiaors (probably Chinese) but it looks good. Should be able to last at least one kid.

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Next up is the carb. For $21.99 I ordered a brand new one off of Amazon (https://www.amazon.com/gp/product/B00MPDNGKQ/ref=ppx_yo_dt_b_asin_title_o04_s01?ie=UTF8&psc=1)

Crazy how you can get a whole new carb for less than a rebuild kit. Maybe playing with fire, but for just over $20 I figure it's worth the gamble. I did one on my Z50R and was impressed so I figure I will give it another go. I do have another question... there are two tubes coming out of the top. What are these hose barbs for? (RED highlight) I figure one is a vent. What is the other? Also, GREEN is the oil input I assume?

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Next up, put some 2 stroke oil (we use just normal 2 stoke mix, right?), quickly bolted on the gas tank and put in some 32:1 pre mix. My idea is to run pre mix until I know 100% that the auto oiler is working. Right now it's just dandling off to the side and once I see it start dripping I will drain the tank, put that gas back into the weed eater can, and fill with straight gas. I haven't used the bleed screw yet...gunna try that.

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Then I fired it up. Used a quick squirt of starting fluid until it fired and turned over a few times under it's own power. Then turned the gas on, and kicked it again. Started right up. Ran for about 20 to 30 seconds....and then quickly turned it off. I freakin forgot to put in the crankcase oil.

Didn't run very long, didn't actually ride it, so I doubt there is any damage. Couldn't have been good for it. I didn't have an air filter or ANY exhuast, and it was so loud it actually hurt my ears, and it was close to 9 PM so luckily I didn't run it too long. But dang, sometimes I'm a moron.

Crank case now has fresh new 10W30. Ugh.

But lets end on a happy note.

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Quickly set the plastics on top. DAAAAANG this looks good. I was honestly worried about going with the black plastics. Didn't know if it would look good. But now seeing it I think I made the right choice. (Well, Peyton chose, but with some minor coercion. )

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More to come. Stay tuned.

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Edited by crane550
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