Father & son's first project: '93 Honda XR80R

[smier]

My son(8) always wants to help work on things, and I try and let him, but sometimes it's either too physically hard for him, or it's too technical for him to grasp just yet. So I wanted to find something simple that we could work on together, that would teach him basic mechanical skills, build a sense of accomplishment, and would just be frigging awesome to ride at the in-laws property!!! So I picked up this beast a few days ago (sorry for the crappy pic, it's from the ad):

I took it to work the next day and washed it in our wash bay, it was dark and cold until I got home, so last night we drained the gas tank and lowered it down the basement steps so we could get started...

And in about twenty minutes he had it stripped of all the fenders, side covers, and seat.

Tonight he gets to learn how to drain and change the oil, replace the spark plug, and clean out the air box and check the air filter. I have a feeling the filter is pretty bad from how it runs right now. I'll probably order a K&N filter for it when I order the new front and rear tires, the front tire is pretty low on tread, the rear isn't much better.
The plan is to clean up everything and paint the frame, plastics are in worse shape than I originally thought, but not too bad, so we will just paint them for the time being. I'll order some new fenders, side covers, and decals after he gets a few tumbles out of the way... We have only had it three days and we are both having a blast!!!
Anybody know how to install a throttle stop? This things got a fair amount of get up and go, and apparently a top speed of around 50 mph... I have to knock it back a bit for safety, and to keep mom happy!

 

[dhcomp]

get up and go, and apparently a top speed of around 50 mph... I have to knock it back a bit for safety, and to keep mom happy!

Sound like a fun project! You could always put a bolt through the handle bar as a stop, but really, if you are working on it together, he'll know what your are doing. Maybe a good chance to teach him to ride responsibly?

 

[smier]

Riding responsibly is a must, we already have been working on a contract. Break the rules, the bike goes bye-bye... I plan on teaching him riding skills slowly, and he already understands that he has to earn being able to ride the bike. He's a great kid, but he's still a kid.
My dad gave me a '78 yamaha enticer 340 snow mobile at age 10, I could hardly steer it. I almost put it thru the back patio doors of our house one day. I won't make the same mistakes my dad made. Heck, we had to beg my dad to get us a helmet...

 

[folkenheath]

Nice project! Is there a way you can adjust the throttle cable so it wont transmit full throttle to the butterfly?

I would just make sure he wears his helmet alll the time. He probably won't go faster than he is comfortable with anyway.

When I was a kid my Dad got an old 100 dirtbike for us. Don't even remember what model it was. I just remember it was so big my feet were a foot from the ground when I sat on it, so I had to stop on a steep sidehill or near a ledge or somethnig so I wouldn't fall over when I stopped, since by the time my foot would touch the ground it was already going over. But I think it made me a better rider quickly. I was always scared when I would climb steep hills because I knew if I lost traction or started to flip over backwards I was going to tip over for sure when I let off the gas. Rolling down a hill backwards on a dirtbike not being able to reach the ground is not a comfortable feeling.

 

[dhcomp]

Theres got to be a place where hte cable is exposed and moves, where you could find a crimp type stop with a set screw. Set stop, and cable would hit bracket before it gets pulled all the way to WOT.

 

[smier]

That's what I'm hoping, I actually thought the 80's had the throttle stop built in, I know the smaller 50's used to? It may not be necessary, he figured the clutch out on his third try. I just remember the first time I accidentally lifted the front tire on a motorcycle, and how I had a death grip on the handle bars and wouldn't let off the throttle!!! I guess you never forget that moment of terror, which can sometimes be a good thing.

 

[dhcomp]

That's what I'm hoping, I actually thought the 80's had the throttle stop built in, I know the smaller 50's used to? It may not be necessary, he figured the clutch out on his third try. I just remember the first time I accidentally lifted the front tire on a motorcycle, and how I had a death grip on the handle bars and wouldn't let off the throttle!!! I guess you never forget that moment of terror, which can sometimes be a good thing.

He'll only screw up once

 

[smier]

He'll only screw up once

I'm still surprised that my wife and my mother-in-law both agreed that it was ok to get him a dirt bike. So last night my wife turns on Americas funniest home videos, and of course they show a montage of clips of people who obviously are new to dirt bikes wrecking into things, flipping, and falling off the back after doing a wheelie... My wife looks at me, I smile and laugh nervously, then she shoots me this look of impending doom/I'll kill you if my baby gets hurt.

 

[swettysblazer]

My uncle put a hose clamp on the throttle for his little 80 so my cousin could ride it. It stopped the throttle from turning all the way. it worked pretty well

 

[smier]

So this is the fuel tank, it's made of plastic which is great because it won't rust or dent, but as you can see, it's not the most attractive tank I've ever seen. It has some scratches and some discoloration from the sun(you can see where the original decals were), as well as some discoloration from the gas. I'm thinking I can sand the tank and paint it, but what kind of primer and paint should I use on the plastic? Will regular automotive paints work? I'm just worried about the paint holding to the plastic well, it's a different plastic material than the side covers and fenders. It doesn't have to be showroom perfect, we are going to cover most of the tank with new decals anyway, but this thing looks bad the way it is now.

 

[dhcomp]

Scuff it up, and hit it with a plastic specific spray paint. Should hold fine.

 

[sweetk30]

clean and prep the hell out of it from the gas thats spilled on it. or the paint can lift back off.

just had this happen at friends shop on a old gas pump respray job. the side panel and top were the globe goes on paint didnt stick or spider cracked bad from all the years of gas fumes soaking in. had to strip it 100% to metal and seal the hell out of it and then it held new paint. the front/back and non fuel hose side panels had no problems with over paint on old paint.

 

[smier]

I think you are right, and after some searching I found this:

http://www.4strokes.com/tech/plastic_restore/

I know I'm probably crazy for doing this, but it's my sons first project, and I want it to be something he can look back and say we did a good job on, even though it will most likely get ruined...

 

[smier]

I think I will order these decals tomorrow:

I have to make quick progress on this project, my son being the typical 8 year old, can't envision the final product. All he sees is an old beat up bike that I keep promising will be awesome.

 

[swettysblazer]

Whatever you let him do, show him how the throttle works first...

My dad got my brother and I a mini bike when I was about 10. Got in it, put the helmet on, and proceeded to haul ass into a tree lol

 

[sweetk30]

tell your son he plays his card right he can work his way up to a big boy toy.

i started on a honda trx 70 4 wheeler. then a 200s 3 wheeler and next was a 250sx 3 wheeler ( god i miss that ) and last and only one i have left 87 suzuki lt500r quadracer ( aka quadzilla )

dad was a little crazy gave it to me for xmas gift when i was about 13 years old ( first pic ) then i fully restored it years later and was testing it out in ( second pic ) wasnt even trying and front come right up on me.

still got the old girl and modifyed to add 20 more hp and now 60hp at rear wheels. man what a ride

 

[smier]

My son cleaning some parts he took off:

The boy turning some wrenches!!!

Made my day!!!

 

[smier]

I had to upgrade the beer fridge in the man cave...

 

[smier]

So I have been working on my '75 Yamaha DT125 Enduro at the same time a we have been working on my sons bike. The other day I noticed Chief Brody using molasses to remove rust on his vent windows. So I decided to give it a shot on my old rusty fuel tank!!!

I mixed it 4 parts water to 1 part molasses, and 3&1/2 days later:

It's pitted, but shiny clean metal!!! I would mix it a bit stronger next time, and I would start by shaking some BB's or sand in the tank to try and bust some of the heavy flakes loose first. So I rinsed it out really good, and since my wife is out at the store:

I'm using the oven to dry all the moisture in the tank before I put the can of tank liner in!!! Shhhhh, she'll never know... For the record, I had previously used a liner kit on this tank, but the acid didn't take it all out. I'm going to call it good and use the liner I have left from the kit.

 

[smier]

It's a beautiful thing, now I can repaint my tank and not have to worry about clogging my carb up anymore!!!

I haven't decided on if I'll put the decals back on the yamaha tank, I love the '70's look, but they are pricey... The cheapest I've found is about $65 on eBay.