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80s Suzuki DS80 rebuild has begun!

  1. #1
    TWINS! xrocket21's Avatar
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    80s Suzuki DS80 rebuild has begun!


    The start!

    80s Suzuki DS80 rebuild has begun!-20200527_160809-jpg

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  2. #2
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    1 hour later

    80s Suzuki DS80 rebuild has begun!-20200527_175902-jpg

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  3. #3
    Lifer loudbeard's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Have any interest in a 1982 KDX80? I'm going up to the lake house in Greene, ME later this month for an easy pickup.

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    I went to MMI I know what Im doing here chief

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    Soul Rider Paul_E_D's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    I remember those! Oh, and an 82 KDX 80 was a killer bike!

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    Paul_E_D


  5. #5
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by loudbeard View Post
    Have any interest in a 1982 KDX80? I'm going up to the lake house in Greene, ME later this month for an easy pickup.
    Maybe.... I guess PM me the details?

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  6. #6
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Of course had to drill out a bolt. These Phillips heads will be replaced with stainless hex head.


    80s Suzuki DS80 rebuild has begun!-20200527_182827-jpg

    This old girl hadn't been cleaned for years then sat for a decade.

    80s Suzuki DS80 rebuild has begun!-20200527_184253-jpg

    I just need to find a throttle tube. this one is partially broken and I worry about the throttle sticking.

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    Last edited by xrocket21; 05-28-20 at 12:10 PM.

  7. #7
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    How it sits now

    80s Suzuki DS80 rebuild has begun!-20200527_193032-jpg

    I plan to clean up the frame and hit it with blue rustoleum

    80s Suzuki DS80 rebuild has begun!-20200527_194053-jpg

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    Last edited by xrocket21; 05-28-20 at 06:39 PM.

  8. #8
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Get yourself an impact driver, and a set of JIS screwdrivers, you'd be amazed how many of those stubborn 'phillips' head screws you thought you'd have to drill out come out without any drama after.

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  9. #9
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by Kurlon View Post
    Get yourself an impact driver, and a set of JIS screwdrivers, you'd be amazed how many of those stubborn 'phillips' head screws you thought you'd have to drill out come out without any drama after.
    I don't have official JIS this big, but I tried drivers of various home grinds. I also hit it with the impact driver with no luck. Of course it was the one partially obscured by the foot peg so I couldn't get a good purchase on it. I should have hit it with the blue tip wrench, but I thought the cover was plastic. Got the head mostly cut off with my dremel, but the battery died of course. It drilled out in pretty short order.

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    Last edited by xrocket21; 05-28-20 at 06:45 PM.

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    Re: 80s Suzuki DS80 rebuild has begun!

    The new parts pile

    80s Suzuki DS80 rebuild has begun!-20200530_150516-jpg

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  11. #11
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Where's the ported big bore cylinder and piston?

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    Re: 80s Suzuki DS80 rebuild has begun!

    Got her down to frame! Cleaned everything with a pressure washer a tub of soapy water. Oil tank had 1/4" of sludge on it. Decided without sandblasting the frame, id never get it good enough to paint so im leaving it.

    80s Suzuki DS80 rebuild has begun!-20200607_110500-jpg

    Painted a few bits I could wire wheel good.

    80s Suzuki DS80 rebuild has begun!-20200607_183453-jpg

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  13. #13
    Lifer LuvDog's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    You could try some Paint stripper. I’ve used the citrus based stuff before and it worked well

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    Lifer JohnnyV's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    This was my DS80 hotrod project from years ago. Fun little bikes


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    Re: 80s Suzuki DS80 rebuild has begun!

    80s Suzuki DS80 rebuild has begun!-20200609_124402-jpg

    Cleaning up and repacking the steering head bearings. The lower balls went EVERYWHERE on disassembly!

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  16. #16
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    Re: 80s Suzuki DS80 rebuild has begun!

    What should I use for replacing the oil in the bottom end of the motor/tranny?

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  17. #17
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by JohnnyV View Post
    This was my DS80 hotrod project from years ago. Fun little bikes

    Youre making me wish I painted the frame


    Looks badass though

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  18. #18
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    I think as long as it's clean oil, the sky's the limit? IIRC the factory called for 10w40.

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  19. #19
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by Kurlon View Post
    I think as long as it's clean oil, the sky's the limit? IIRC the factory called for 10w40.
    Just plain 'ol motor oil?

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  20. #20
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Motor oil, ATF, 80/85w gear oil, it's a splash lube gearbox and clutch, no plain bearings or pumps/etc so it'll be VERY tolerant of just about anything. About the only item to put any thought into is the clutch, an oil with excess say, Teflon I'd avoid.

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  21. #21
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by Kurlon View Post
    Motor oil, ATF, 80/85w gear oil, it's a splash lube gearbox and clutch, no plain bearings or pumps/etc so it'll be VERY tolerant of just about anything. About the only item to put any thought into is the clutch, an oil with excess say, Teflon I'd avoid.
    Thanks man! I think tires should be in this week, I need to clean the carb in the motor and do that fluid/plug change, a little more re-assembly, and I should be kicking it over by the weekend!

    I was given a couple gallons of marine 2-stroke oil, I assume I can use that in the oil tank on this? I mean, its a 1985 smoker, how picky can it be?

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  22. #22
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Make sure it's injector oil, and not intended for premix use only. You don't want to gum up the pump and starve the top end of oil after all this effort.

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  23. #23
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    80s Suzuki DS80 rebuild has begun!-20200609_160428-jpg

    80s Suzuki DS80 rebuild has begun!-20200609_161036-jpg

    New sprocket vs old sprocket!

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    Last edited by xrocket21; 06-09-20 at 04:14 PM.

  24. #24
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by Kurlon View Post
    Make sure it's injector oil, and not intended for premix use only. You don't want to gum up the pump and starve the top end of oil after all this effort.
    80s Suzuki DS80 rebuild has begun!-20200609_171026-jpg

    I didn't even realize it was Amzoil till I took the pic lol. Got 2 gallons free. It is injector so it should work. The gn4 I use on the rc51 so I have spare. Might use the castrol too as it was free and I have no other use for it.

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    Last edited by xrocket21; 06-26-20 at 10:16 AM.

  25. #25
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    The cloth seat strap was tucked underneath, and other than being wrinkly from being tucked, looks pretty new from being hidden. Should I re-attach it so it goes over the seat, or keep it tucked? I feel like its a good handle for picking up the rear and might keep little buns from sliding off the back when the powerband kicks in, but it also looks pretty clean without it.

    Thought?

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