pw80 mods

[clownpuncher]

Here are Mods That I'm doing to my PW 80

Here's the list;

Renthal Handel bars 7/8 dia. Got them on www.craigslist.com for a Honda CRF 450.

Renthal Grips

Raised the oil level 6.5" from top and use 15 wt fork oil - Not done yet

BBR front and rear springs - Not done this yet

TTR90 modified foot pegs - steel cleated - Not done this yet

FMF fatty pipe and PC2 silencer - Not done this yet

Starcross tires - Not doen this yet

Blue plastic from ww.PWonly.com I will change them out to Black!

Factory Effex seat cover with Factory Effex sticker Kit - This was easy to do see Video off www.factoeryeffex.com web site under videos.

Removed oil injection pump gear and oil tank and blocked hole in carb and pump. - Not done this yet
Premix 40:1 Sunoco 94 pump gas
.020 over Wiseco piston kit - Not done this yet
Ported cylinder - raised exhaust port 4 mm widened 4 mm each side
- Opened the exhaust port to match the FMF pipe
- Polished the exhaust port
- polished intake and transfer ports
- matched transfers to piston and smoothed transition.
Machined 4 mm from the head and reshaped the dome squish band 10 deg and relieved 4 mm
Static compression is now 185 psi.

Boyessen reeds P/N: 673 - This took about an hour to do, very easy.

Ditched the K&N clamp on filter as it doesn't like mud.

Cut 4 1" holes in stock airbox and covered with foam. I did this and took about one hour and it was simple, you can buy the small 1 inch port filters, they are called UNI.

Main jet is a 140 now with the engine mods Pilot is a 35. Needle in middle. In the process of doing this right now!

48 tooth rear sprocket and stock 15 counter shaft Note: Tried 14/48 but it makes 1st gear totally useless. I might try a smaller rear sprocket with the extra power. 3rd tops out way too soon.

This bike rips now - even with my 160 pounds on. It'll wheelie very easily. The powerband is still very wide and has a ton more power. Porting is definitely the way to go. I mainly used a Dremel and carbide bits.

Update: Changed the rear sprocket to a 45 tooth now it geared properly. First gear is usable now and pulls nicely. The gap between gears is reduced. Each gear pulls longer. Very nice.

[clownpuncher]

Hello everyone I just changed out my Handlebars out to Renthal. I got them off www.Craigslist.org they were off a Honda CRF 450. The bike looks sweet but more important the bike is comfortable. Next I plan on changing the top triple clamp located here. x-tender.com/triple.html. I also plan on lifting the front forks and rear shock.

I will start to load how to videos on www.youtube.com to show people how to perform the mods.

[clownpuncher]

Hello everyone today I went and bought a 13T Moose front Sprocket, 45 Moose rear sprocket and a Renthal 420-120 chain. I will be installing it next week and it should give me fast pick up off the start but lower top end speed.

[clownpuncher]

Today I installed Boysen Reeds which was very simple to do. I had to take the engine out with three bolts then remove the intake, popped in the new Reeds and I'm all set.

I'm looking for a 2001 carb and a 1985 to 1995 CDI if anyone has one let me know??

[clownpuncher]

Hello today I install a 120 main jet adjusted the needle one noch down from stock. I have not started but will do it tomorrow. I need an FMF pipe and silencer anyone have a set for sale? I'm also going to port and polish my intake and exhaust port.

[clownpuncher]

Okay I have not tuned my bike yet but it rips now, what a difference in the Air Box Mod, Carb 120 main jet and Boysen Reeds. This bike has come alive and seriously RIPS. I need to get a FMF pipe kit and a older CDI to stop the REV limiter. My big issue right now is the Rev Limiter.

I love the 13 tooth front sprocket with the Renthal 420x120 chain huge difference in pick up!

ANYONE have a CDI for sale between 1985 to 1990 let me know!!!!

[mod80]

mods I've done:
Head milled down as much as possible but to still allow proper specs for squish band.
Ported & Polished intake and exhaust.
Exhaust matches the FMF exhaust pipe.
Boyesen power reeds.
Airbox ports
Oil injection removed
Mainjet gets switched depending on season and use. 125 - 145
pilot is a 35 I BELIEVE. its been awhile since I've done all this.
.40 over wiseco piston
a few balls removed from clutch to raise the stall
monster racing ignition coil
back suspension mod to raise roughly 2" in the rear
3 different back sprockets for whatever purpose may be. stock - 45 - 48
stock front sprocket.

with the stock sprocket set-up the bike tops out at 62 mph. IMPRESSED!!!!!

[clownpuncher]

How did you do the port and polish what did you use and how hard was it?

[clownpuncher]

FYI:

So the TTR 90 Front fender does not bolt right on you need to modify the front bracket.
The body does not fit either.
The gas tank is 399.00 new so that is an expense.

So far I've put the front fender on and it looks good.

[6531quad]

Did you disconect the cable from the oil pump?
And can anyone tell me where to get a solid cable for just the carb, and length?

[clownpuncher]

No I'm not premixing. The bike is now for sale it rips. Just needs FMF pipe.

[thenuttyprofessor]

I replace my front end with one meant for a CRF50. I changed to a 12 inch instead of the 14. Now I just need to find street tires.

[Andre]

How much for the bike?

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