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and a final before and after

Better late than never?? I never finished posting the final pics of this build. Here are some pics of the completed bike.

petcock: https://www.amazon.com/gp/product/B076WZ49QQ/ref=ppx_yo_dt_b_search_asi… As for the spacer between the shock reservoir and the frame, I designed something then 3D printed that part and painted it. I couldn't find an off-the-shelf, good-condition one anywhere. I'd be happy to provide the stl file to be printed. Just dm me if you'd like it. thanks

@Pgd09yz450 Thanks! I just used Rust-Oleum primer and paint on the engine, nothing special. I did some looking at their website and found that the temp range seemed high enough, but not super high. I'm not sure how often this bike will run after this rebuild anyway. One thing that has worked great for me is their acid-etch primer. For...

I purchased the 4 3/4" tool. It was plenty for the job and I am not usually clamping on very large diameter fittings which would require the bigger tool. I probably could have made one, but I figured I'd splurge. here is a pic:

Finally, caught up. This is the current status of this project as of today. The items left on the punch list are: - Radiator strut - Radiator shroud finalization (the plastic over the radiator) - Lower chain guide 3d print of final design - Put on all the stickers. - Fire it up and see if anything needs to be...

While doing this project, I decided I didn't like the look of hose clamps. So I bought a clamptite tool which uses stainless steel wire to make a nice looking and better working clamp. Here are examples of the places I used it around the bike. One includes the exhaust clamps that I previously crimped. I removed the crimp connections...

After not being able to find a new condition 1986 KX80 radiator, I found that a 1989/1990 KX80 radiator has the same mounting style. These are available as an aftermarket part, so we went with it. Similar to mounting the fuel tank, the hardware store had some rubber grommets that worked perfectly to mount the radiator. And, a trip to...

The rest of the plastics came in...

One of my biggest worries on this job was the plastics. I tried cleaning them up for quite a while, using all types of methods like starting with a razor blade, wet sanding, torching, etc... Nothing made the plastics look clean enough to be on the bike considering how the rest turned out. So we made the decision to purchase...

after doing some homework on forums, I decided to use ATF Type F in the gearbox. The red oil in the sight glass looks cool.

Had to get inventive on the rear brake cable. It wasn't available anywhere, and the original was damaged and beyond a good clean up. So, I use some swageless wire rope fittings used on wire railings. They are all stainless, and I think it turned out pretty good. in the first two pics, the original cable shown along with the...

Another thing to deal with, the mud flap rubbed against the chain. I ended up slotting the holes in the flap and shifting it over a bit so everything fit with some healthy clearance. It is barely noticable

Well found one weird problem... The new rear sprocket had a mistake in the machining of it. A few teeth didn't line up. Fortunately, the seller was super helpful and replaced the part as shown in the pics.

Rear wheel assembly came back, so I was able to work on that install. The bike is now rolling once again.

The exhaust was the next thing to cover. The muffler was easy, just a clean up and high temp paint. The pipe however was pretty dented and needed some work to make it look good. I tried a bunch of ways, but it was easiest to just cheat in the end and apply some high temperature epoxy to the dents...

Next big milestone was handlebar and front controls. After doing some searching, we decided to reuse the existing front controls. The brake and throttle are original, but the clutch was not. Still it was more consistent to have them all cleaned up, primed, and painted the same way. New cables and grips,and kill switch purchased, but I reused the brake...

Front brake pads arrived and they were the right ones! This is the 3rd set of brake pads I bought...