1984 xr80

[coolpool]

Picked up a 1984 XR80A dirt bike that's been sitting under a shelter for 10+ years as part of a package deal along with an 18.5" car hauler from a friend. This thing has seen some hard riding but looked complete enough to take a stab at fixing it up......and of course "ran when parked". I'll hopefully flip it for the cost of purchase and parts....so a minimum of ~$1200.00. Some of my co-workers have kids in the 8+ range that want first dibs on it so should be an easy sell. The tank is dented but clean and the carb was miraculously pristine inside. It only had ~60psi compression at first, but after a liberal dose of penetrating fluid in the cylinder, a little heat on the jug and kicking for a bit it jumped to ~140psi and took right off. That gave me the go-ahead for a full tear down.

The Bad
Foot peg mount is being held on by one bolt and bent as well as one mount hole ripped through. One foot peg is also homemade
Seat cover pooched
Missing side covers
Needs both control levers
SAE bolts holding the engine in
Missing skid plate
Chain and sprockets worn
Grips worn out
Steering stop broken off (i.e. dented tank)

The Good
Runs
Tank is clean
Carb is clean
Seat pan is perfect
Seat foam is OK
Tires are good
All control cables are good
Brakes are good
Forks are good
Exhaust is good (small dent in header pipe)

[ScreaminRed]

My father bought me a '79 xr80 new. That was a great dirt bike. Never had an issue the 4 years we owned it. Good luck, and should be an easy sale!

[coolpool]

Update: Got the front steering stop welded on and found an almost perfect match of paint with VHT Caliper Paint - Orange......close enough to clean up the rusty frame. Been doing lots of cleaning and painting and have a few new parts to put on, grips, levers, chain & sprockets, etc. I now know I need some rear bearings and it looks like the rear tire tube I bad...got to take the tire off first.

[ATC King]

They're simple, dependable, and durable little bikes.

A friend of mine had one when we were early teens. I had a faster bike and it took me a while to understand why he would make it to my house faster than I made it to his. He rode that XR80 wide open everywhere.

[Footy]

Nice find. I have a set of Maier side covers that will fit that bike that I would sell if interested.
These are the more rounded design like the 1982 model honda but will fit up to 1984 model.

[coolpool]

PM sent Footy, thanks!

[coolpool]

Been slowly tinkering as I alternate between an 18.5' car hauler project and this unit. Got around to the air box which had 2 of the 3 cover bolts stripped from either over tightening or SAE nuts used at some point. I thought of welding around the circumference of the studs and cutting new threads but that seemed too involved. I then thought of cutting them off and drilling them out but that had it's own issues. I decided on bending the tabs up slightly and carefully cutting the stud heads off from behind with a Dremel. the old hardware fell out leaving the original hole. I then took new M6 x 1.0 x 1cm bolts and ground the head off to ~30% thickness and tack welded them in place from behind. A quick bend of the tabs and we're back in business.