Other PW80 Strip down and rebuild

[Mihylo33]

My bike is a 1991.

Probably all the basically the same.

 

[ossagp]

if you go to a site like bikebandit.com they should have the one for your year. As Mi says, they should be all the same.

 

[SRAD97750]

That parts fiche is kind of misleading. The bearings make up quite a few of those items as an assembly.

So you need a bearing and seal kit. I recommend All Balls unless you are set on OEM replacement parts.
http://www.ebay.com/itm/All-Balls-Steering-Stem-Bearing-Kit-Offroad-22-1008-22-1008-/231279147805?pt=Motorcycles_Parts_Accessories&fits=Year:1991|ModelW80&hash=item35d94fbb1d&vxp=mtr

So from the bottom of the lower clamp it goes
Seal
Bearing
Race
Frame Neck
Race
Bearing
Seal
Nut
Top Clamp
Clamp Bolt

I just did this yesterday, but didn't snap any photos for you.
Here's an insightful video.
https://www.youtube.com/watch?v=dYUL4siK82o

-BIG DAN

 

[Mihylo33]

That parts fiche is kind of misleading. The bearings make up quite a few of those items as an assembly.

So you need a bearing and seal kit. I recommend All Balls unless you are set on OEM replacement parts.
http://www.ebay.com/itm/All-Balls-Steering-Stem-Bearing-Kit-Offroad-22-1008-22-1008-/231279147805?pt=Motorcycles_Parts_Accessories&fits=Year:1991|ModelW80&hash=item35d94fbb1d&vxp=mtr

So from the bottom of the lower clamp it goes
Seal
Bearing
Race
Frame Neck
Race
Bearing
Seal
Nut
Top Clamp
Clamp Bolt

I just did this yesterday, but didn't snap any photos for you.
Here's an insightful video.
https://www.youtube.com/watch?v=dYUL4siK82o

-BIG DAN

Oddly enough my first thought was that it was exactly like a bmx bike with all individual parts. Atleast it's what it appears to look like in tht schematic.

 

[diggerdog36]

Yeah I think it is. It needs the cups pressed into the head tube. So this means I can't use the tapered roller bearings.

 

[SRAD97750]

Yeah I think it is. It needs the cups pressed into the head tube. So this means I can't use the tapered roller bearings.

These after market steering stem bearings replace OEM with tapered rollers because they are way more efficient. Press out the old cups, and the new bearing races replace them. -BIG DAN

 

[diggerdog36]

This is the head stock that I have on my bike. I just cant imagine a taper bearing in the top as its so shallow!

 

[diggerdog36]

Here it is ha ha ha!

 

[SRAD97750]

The new bearings will fit right in.
Don't think of them as tapered, as the tapered mating surfaces have absolutely zero to do with your bikes design. The tapered part is inside the bearing, and defines the type of bearing. The overall dimensions of the bearing will be identical to what you removed.
The race will fit right in the head stock, and the bearing will fit over the steering stem.

FEAR NOT. For we are with you. -BIG DAN

 

[diggerdog36]

I sprayed a few parts today. Here is the gearbox cover. The rainbow effect is the reflection of a kite hanging from the roof!

 

[diggerdog36]

Forks blasted and sprayed and finished!!

 

[diggerdog36]

Right ive rebuilt the engine (motor for you wrong'uns accross the pond!) with new seals and bearings. Im all ready to rlbegin the rebuild tomorrow. So, ill keep you's updated!

 

[diggerdog36]

Well, the Engine is mounted in the frame and........we have a spark. So were one step ahead of when I bought the bike!!

 

[diggerdog36]

I need a new brake lever and perch for my PW80. Is the lever smaller than a normal adults bike or will any lever and perch do?

 

[Mihylo33]

I need a new brake lever and perch for my PW80. Is the lever smaller than a normal adults bike or will any lever and perch do?

That's a good question but I suppose that it's normal size as my front brake lever for my KX250 is the same part# as the kx65