Brother Billy's 1980 xr80 - Page 3

Weldangrind · 12-09-2011, 10:23 AM

It's not so much elevation in your case as the rotten muffler. Do you plan to fabricate a new muffler?

katoranger · 12-10-2011, 08:59 PM

I think first step will be making sure it runs. Then I may do something about the exhaust. I have a newer xr80 exhaust that maybe could be made to fit.

Or open it up and rejet.

katoranger · 12-12-2011, 02:36 PM

I opened the air box to find the remnants of a filter. Ordered a new one. Hopefully it comes by the end of the week.

Thinking more on the muffler. I have the new xr80 pipe. They are a dime a dozen compared to the older ones for the twin shock models.

I am wondering if I can cut the end off of the new one and slip it over the original using the baffle from the newer pipe.

The stock exhaust seems pretty solid until the last six inches. The inside look shot. Probably loud too.

katoranger · 12-12-2011, 03:16 PM

I think I can make this work.

I cut a late model xr80 exhaust off at the forward seam. This was a dented up one that didn't have any ebay value. Looks like it has a use now.

Inside the late model xr80 muffler.

The newer one is straight. The older one is tapered some. I think I can slip it on and weld it around at the end.

Weld, I don't have your skills at fabbing a whole new part. This will have to work.

katoranger · 12-12-2011, 04:07 PM

Looks like its going to work.

I just went out and started cutting. Did some grinding and maybe later some welding.

I made some slits for the baffle mounts to slide into.

Also ground a slot for the hanger on the other piece.

Now I need to decide how to secure it together. I am almost afraid to weld it. The metal is so then on the old exhaust. Thinking about some keep of muffler putty and pop rivets.

FastDoc · 12-12-2011, 04:40 PM

The muffler putty will likely work OK in that application. It will hold the pressure, but it's brittle and will crack/flake off if there's any movement.

It's been holding the multiple holes/repairs on The Dirt Rat 2, but I will be looking at a replacement muffler after work tonight.

FastDoc · 12-12-2011, 04:42 PM

I bet red RTV silicone would be better, especially if the gaps are not too large that need to be filled. This will take the inevitable flexing and vibration better I think.

It seems to take heat OK. My BSA mechanic uses it on the slip joint where the header inserts into the head on all the BritBikes he does.

katoranger · 12-12-2011, 05:27 PM

Red RTV might be the answer. It is pretty ridgid slipped together. The RTV with about a dozen rivets or self-tapping screws may be enough.

New points installed. Set gap. Sprayed a touch of carb cleaner in the intake.

One kick and it fired up. :wink: Looks like we have a runner. Need to get some tires coming.

FastDoc · 12-12-2011, 05:54 PM

Hey great news!

You gotta love the Honda XR line!

katoranger · 12-12-2011, 06:46 PM

Carb installed. Required a few steps and parts from original to fit.

I had to swap the choke handle so it would clear the frame and install the two mounting studs from the original carb. Also used the original top piece of the carb since it is straight and not curve. Other than that it seems to be a bolt in.

Next I need to flush out the tank and install a new fuel line and filter.

The cable seems to hang up. I recommended a new one after as part of the restoration.

FastDoc · 12-12-2011, 06:55 PM

Awesome!

What's with the oil leak? Just the valve cover gasket?

katoranger · 12-12-2011, 08:12 PM

I sprayed some penetrating oil down the cylinder. That is what sprayed out after giving it a few kicks.

Lubed the top end some.

Weldangrind · 12-12-2011, 08:56 PM

Perhaps you can practice welding on some of the remnants that you cut away. I'll bet that your Hobart would do a fine job. If you're not satisfied with the results, you could certainly rivet it together.

I got an excellent tip from a gentleman on the TS forum that Kato found. He puts a really thin film of grease on any gaskets, which helps to seal and makes them reusable. If you need to remove the valve cover, perhaps you would benefit by applying a thin film of grease to the gasket or o-ring.

Glad to hear it runs! Have you found a rear fender yet?

SpudRider · 12-13-2011, 12:20 AM

The new carburetor looks great! I agree with FastDoc; you have got to love the Honda XR motorcycles!

Spud

katoranger · 12-13-2011, 08:21 AM

I am going to try and weld it. The practice on a some of the scrap is a good plan. I can get the hobart set up on that.

This may be a Thursday activity.

Grease on the gasket. Good idea. I think I will be checking to valves while it is here too.

12-09-2011, 10:23 AM	#31
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	It's not so much elevation in your case as the rotten muffler. Do you plan to fabricate a new muffler? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

12-12-2011, 04:40 PM	#36
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	The muffler putty will likely work OK in that application. It will hold the pressure, but it's brittle and will crack/flake off if there's any movement. It's been holding the multiple holes/repairs on The Dirt Rat 2, but I will be looking at a replacement muffler after work tonight. __________________ Happy to serve.
	0

12-12-2011, 04:42 PM	#37
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	I bet red RTV silicone would be better, especially if the gaps are not too large that need to be filled. This will take the inevitable flexing and vibration better I think. It seems to take heat OK. My BSA mechanic uses it on the slip joint where the header inserts into the head on all the BritBikes he does. __________________ Happy to serve.
	0

12-12-2011, 05:54 PM	#39
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Hey great news! You gotta love the Honda XR line! __________________ Happy to serve.
	0

12-12-2011, 06:55 PM	#41
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Awesome! What's with the oil leak? Just the valve cover gasket? __________________ Happy to serve.
	0

12-10-2011, 08:59 PM	#32
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I think first step will be making sure it runs. Then I may do something about the exhaust. I have a newer xr80 exhaust that maybe could be made to fit. Or open it up and rejet.
	0

12-12-2011, 02:36 PM	#33
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I opened the air box to find the remnants of a filter. Ordered a new one. Hopefully it comes by the end of the week. Thinking more on the muffler. I have the new xr80 pipe. They are a dime a dozen compared to the older ones for the twin shock models. I am wondering if I can cut the end off of the new one and slip it over the original using the baffle from the newer pipe. The stock exhaust seems pretty solid until the last six inches. The inside look shot. Probably loud too.
	0

12-12-2011, 03:16 PM	#34
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I think I can make this work. I cut a late model xr80 exhaust off at the forward seam. This was a dented up one that didn't have any ebay value. Looks like it has a use now. Inside the late model xr80 muffler. The newer one is straight. The older one is tapered some. I think I can slip it on and weld it around at the end. Weld, I don't have your skills at fabbing a whole new part. This will have to work.
	0

12-12-2011, 04:07 PM	#35
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Looks like its going to work. I just went out and started cutting. Did some grinding and maybe later some welding. I made some slits for the baffle mounts to slide into. Also ground a slot for the hanger on the other piece. Now I need to decide how to secure it together. I am almost afraid to weld it. The metal is so then on the old exhaust. Thinking about some keep of muffler putty and pop rivets.
	0

12-12-2011, 05:27 PM	#38
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Red RTV might be the answer. It is pretty ridgid slipped together. The RTV with about a dozen rivets or self-tapping screws may be enough. New points installed. Set gap. Sprayed a touch of carb cleaner in the intake. One kick and it fired up. :wink: Looks like we have a runner. Need to get some tires coming.
	0

12-12-2011, 06:46 PM	#40
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Carb installed. Required a few steps and parts from original to fit. I had to swap the choke handle so it would clear the frame and install the two mounting studs from the original carb. Also used the original top piece of the carb since it is straight and not curve. Other than that it seems to be a bolt in. Next I need to flush out the tank and install a new fuel line and filter. The cable seems to hang up. I recommended a new one after as part of the restoration.
	0

12-12-2011, 08:12 PM	#42
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I sprayed some penetrating oil down the cylinder. That is what sprayed out after giving it a few kicks. Lubed the top end some.
	0

12-12-2011, 08:56 PM	#43
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Perhaps you can practice welding on some of the remnants that you cut away. I'll bet that your Hobart would do a fine job. If you're not satisfied with the results, you could certainly rivet it together. I got an excellent tip from a gentleman on the TS forum that Kato found. He puts a really thin film of grease on any gaskets, which helps to seal and makes them reusable. If you need to remove the valve cover, perhaps you would benefit by applying a thin film of grease to the gasket or o-ring. Glad to hear it runs! Have you found a rear fender yet? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

12-13-2011, 12:20 AM	#44
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	The new carburetor looks great! I agree with FastDoc; you have got to love the Honda XR motorcycles! Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

12-13-2011, 08:21 AM	#45
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I am going to try and weld it. The practice on a some of the scrap is a good plan. I can get the hobart set up on that. This may be a Thursday activity. Grease on the gasket. Good idea. I think I will be checking to valves while it is here too.
	0