1986 Kawasaki KX80

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4/24/2020 6:08 PM
Edited Date/Time: 5/31/2020 1:13 PM

My "corona project".

I'm restoring my brother's KX80 which has been around the family as far back as I can remember.

I'll post pictures as the job progresses

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4/26/2020 6:40 AM

Here is a pics of the bike before I started. Photo

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4/26/2020 7:04 AM

A few more before photos Photo
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4/26/2020 7:13 AM

some close up "before" pictures

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4/26/2020 7:18 AM

and more...
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4/26/2020 7:20 AM

rear hub tear down
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4/26/2020 7:25 AM

more general disassembly
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4/26/2020 7:27 AM

front wheel assembly Photo
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4/26/2020 7:30 AM

everything got a bath in simple green and hot water with an agitator pump.
Found a crack in the frame at the top shock mount.
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4/26/2020 7:37 AM

It all came out pretty clean. At least clean enough for the next steps.Photo
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4/26/2020 7:47 AM

Next, was rear shock tear down. I wanted to open it up and clean it up so I could spend time finding and buying the correct replacement parts. One part that really had me confused was the separate accumulator, I could not find any good literature on what was going on inside there and where to find parts for it. Turns out it's a simple piston and cylinder assembly.

The piston was stuck down near bottom of the cylinder it took a lot of work to remove it. I finally got it out my tapping it down, deeper into the cylinder to free it up and then using a compressor at about to push it out. It has a big fat o-ring that I could not look up anywhere, so I took some measurements and cross referenced it.

Once figured out, the parts needed were put on order and it was set aside.

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4/26/2020 7:52 AM

The next big decision was the wheels...

The spokes were all corroded, and the rims were pretty dinged up. It was clear that the spokes had to be replaced at the least. The spoke nuts were all rusted, so I just cut them all to make disassembly easier.

At this point I focused on cleaning up the hubs.

Pending the outcome of the rest of the job we would decide on new spokes + rims or just new spokes and cleaning up the existing rims.

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4/26/2020 7:58 AM

The front rotor was pretty expensive to buy online. It wasn't in bad shape so I decided to clean it up instead.

I didn't want to be too aggressive with a clean up and make it feel warped, so I did a light sanding, and painted it. I taped off just smaller than the pads would wear.

I primed it and painted it black.

If it doesn't look right it can always be changed out later.

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4/26/2020 8:06 AM

Time to do the weld repair on the frame.

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4/26/2020 8:12 AM

The swing arm was pretty dinged up, so I took some time to file out the dings, and decided it should be painted.

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4/26/2020 8:21 AM

Next was a thorough sanding for the swing arm, front shocks, brake linkage and sub-frame.

After masking anything that needed it and hanging them for paint, I primed them all. I used a self-etching primer for the parts that I took down to bare metal.

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4/26/2020 8:27 AM

Next I replaced the bearings in the front and rear hubs. To do that I had to fix up the spacers that got banged up while trying to get the old bearings out. The bearings were pretty frozen in there over the years. After new bearings, the hubs got sanded down and primed.
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4/26/2020 8:34 AM
Edited Date/Time: 4/26/2020 10:39 AM

Time to do the frame.

Simple green with hot water did a good job taking off any paint that wasn't adhered well. After I used a wire wheel on a grinder to get what I could and the rest of the prep work had to be done by hand.Photo
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4/26/2020 8:38 AM
Edited Date/Time: 4/26/2020 10:39 AM

After, it got a coating of primer.
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4/26/2020 8:53 AM
Edited Date/Time: 4/26/2020 8:54 AM

Paint.

All the primed parts got their paint.

Two colors were used:
Satin Black
Colorrite Kawasaki 458 Metallic Phantom Silver and gloss clear coat

The colorrite paint and clear coat are the best paints I've ever used. They go on easy, no runs, and cover well. The entire job including all the smaller parts shown later, took 2 cans of color and clear.

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4/26/2020 8:59 AM
Edited Date/Time: 4/26/2020 9:01 AM

Triple Clamps and steering stem

I cleaned up the steering stem bearings. And used some metal polish on the triple clamps. I didn't want them super shiny, just cleaned up good.

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4/26/2020 9:01 AM


I also polished up the steering stem hardware.

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4/26/2020 9:05 AM

One of the swing arm caps was missing. And one of the chain adjusters had been modified to have a bolt threaded into it. I was lucky to find a new swing arm cap on e-bay, and I modified the other chain adjuster to have a bolt threaded into it as well.

I painted the caps the same color as the swing arm.

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4/26/2020 9:08 AM

The plastic cap that goes on the steering assembly was pretty scratched up. I tried polishing it and it didn't work out so well, so I scuffed it up real good, primed it and painted it. I hope it holds up. Photo
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4/26/2020 10:14 AM

I took a little extra time on the handlebars. After sanding to bare metal, I put a few coats of filler primer and wet sanded them. Two coats of black paint when on with a wet sanding between them.

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4/26/2020 10:21 AM

At this point I finished all the sanding priming and painting of the miscellaneous other items.
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4/26/2020 10:25 AM
Edited Date/Time: 4/26/2020 6:29 PM

more miscellaneous Photo parts
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4/26/2020 10:29 AM

Airbox restore using sanding, and torch method Photo
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4/26/2020 11:36 AM

Awesome job!! Keep the pics coming!!! I had an '87 KX80. Great bike. Frame and swing arm look like the factory finish.

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4/26/2020 12:15 PM

This is my bike, or was, and is now going to the kids.

We're looking for plastics if anyone happens to know if some decent sources for 1986 plastics - especially side covers and shroud.

Will probably end up reconditioning some parts from eBay, but open to alternatives.

Thanks!

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