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Classic Bike Trackdays

AR 80 Project
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yamfan



Joined: 11 Jul 2016
Posts: 122
Location: Ireland - South east

PostPosted: Sun Feb 05, 2017 11:05 pm    Post subject: AR 80 Project Reply with quote

I have decided to make a start on the AR 80 that I have and thought I might find a sympathetic ear here.

It's been waiting for attention for over four years now.



The engine came dismantled in the sack.


Someone is having a laugh.

I loosely stuck it together and it ran and sounded raspy.


Lockstop requires attention.

The bike was then taken apart(didn't take long) and left for four years.
Time now to spruce it up, on a tight (non existent) budget.
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Top-shaggy
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Joined: 05 Mar 2011
Posts: 1753
Location: Derbyshire

PostPosted: Mon Feb 06, 2017 1:19 am    Post subject: Reply with quote

Brilliant.. another AR being saved
great stuff yamfan:)
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steezin_and_wheezin



Joined: 07 Jul 2015
Posts: 68
Location: Radford, VA(USA)

PostPosted: Tue Feb 07, 2017 3:40 pm    Post subject: Reply with quote

Wish I could find a basket case like that in my parts room! Good luck on the refresh
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yamfan



Joined: 11 Jul 2016
Posts: 122
Location: Ireland - South east

PostPosted: Wed Feb 08, 2017 12:02 am    Post subject: Reply with quote

steezin_and_wheezin wrote:
Wish I could find a basket case like that in my parts room! Good luck on the refresh


Be careful what you wish for Laughing

There are a couple more in there Help



There's not much good in this picture




Rear arm


I have no idea how this damage could have happened

A bit of bashing and it's all good


I try to end posts with something positive, so here is a replacement chain adjuster I made (one was missing)
It's just a small piece of 3mm plate, bent up slightly at the ends and welded to the shank of a M6 bolt. A light tap with the chisel adds the adjustment marks as the original.
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Top-shaggy
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Joined: 05 Mar 2011
Posts: 1753
Location: Derbyshire

PostPosted: Wed Feb 08, 2017 7:32 am    Post subject: Reply with quote

Good job with chain adjuster.. something quietly satisfying about making stuff like that even if it's still available.

Unusual to see ignition barrel in such good condition .. the keys of a thousand 16yo's (read screwdrivers) had no place in its life Smile
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yamfan



Joined: 11 Jul 2016
Posts: 122
Location: Ireland - South east

PostPosted: Wed Feb 08, 2017 9:54 pm    Post subject: Reply with quote

Aha yes, the universal key Laughing

Most of the hardware seems to be available, but where is the fun in that?

I got another set of broken clocks, these were broken on the lower half


Hey presto, a nice set



Did some welding, captave nuts that had come off and also built up the sidestand tab that was worn.
Here is the tab after being ground back.


My bike was missing the rear passenger pegs and frames.
I got some secondhand ones and they were pretty horrible - just like the rest of the bike I suppose.
They got straightened out and I made some new stainless steel pivot pins to replace these. That was a nail used to hold the pins in place.
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yamfan



Joined: 11 Jul 2016
Posts: 122
Location: Ireland - South east

PostPosted: Fri Feb 10, 2017 12:29 am    Post subject: Reply with quote

Started stripping the frame, I have tweaked the foot peg mounts to get them straight and built up the yoke lock stop with weld.



Messy business, a good 3M mask is essential to avoid "the black snot"
Best to make sure everything is straight before painting.

Got this replacement peg made too,


I also had a look at the parts pile, it consists of two plastic tubs. I was sure there was a tub missing but no such luck.

I have an add in the wanted section, If any AR freaks have any spare spares knocking about.
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Top-shaggy
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Joined: 05 Mar 2011
Posts: 1753
Location: Derbyshire

PostPosted: Fri Feb 10, 2017 8:55 am    Post subject: Reply with quote

yamfan wrote:
Started stripping the frame

Messy business, a good 3M mask is essential to avoid "the black snot...


Black snot was free from Kawasaki with every new bike frame in the 70/80s

That's how you know you have a Gud'un


Wink
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The Cameraman



Joined: 22 Aug 2015
Posts: 608
Location: Lancashire

PostPosted: Sun Feb 12, 2017 3:46 pm    Post subject: Reply with quote

Hi Yamfan,

you're doing a fine job there.
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Reggie
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yamfan



Joined: 11 Jul 2016
Posts: 122
Location: Ireland - South east

PostPosted: Mon Feb 13, 2017 1:41 am    Post subject: Reply with quote

Thanks for the encouragement

I haven't done much over the last couple of days as it is 3 degrees out in the garage. I don't mind slightly chilly but under 5 is pushing it.
It the same on the bike, once it gets below 6 or 7 degrees it just too cold for more than 20 minutes. Must get some heated gloves for the workshop Laughing

I prepped the front wheel in the utility room, lots of sanding in little corners.

I will do the back wheel when my finger tips start to grow back.

Made this though, side stand bolt. It was once a wheel bolt for a car! I hoped it would be decent quality steel.


Did some shopping too, half an AR 80 in the post from all corners of the internet.
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yamfan



Joined: 11 Jul 2016
Posts: 122
Location: Ireland - South east

PostPosted: Wed Feb 15, 2017 1:24 am    Post subject: Reply with quote

The swingarm bushes were in a bad way
All five are worn


However the long pivot bush was unworn in the center - so i did what any skinflint would do and chopped it up


Now I just need one long bush instead of five. The bushes are surprisingly soft to cut on the lathe , they are not hardened like some can be.
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yamfan



Joined: 11 Jul 2016
Posts: 122
Location: Ireland - South east

PostPosted: Mon Feb 20, 2017 2:26 am    Post subject: Reply with quote

I got some more dirty work done



The parts look alot better when they are stripped back.
Muck, rust and patchy paint is not a good look.

I managed to spend a small fortune on parts last week - so much for low budget.

I really need to source an AR 80 exhaust and cowl any pointers would be appreciated.
There are a couple of AR50 exhausts available but the prices are high, for what is the incorrect exhaust for me.
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yamfan



Joined: 11 Jul 2016
Posts: 122
Location: Ireland - South east

PostPosted: Thu Feb 23, 2017 12:06 am    Post subject: Reply with quote

Had a delivery today,

It was a surprisingly small box for 300 euro worth of parts, mainly rubber parts, plastic bushings and a bit of foam. Everything was reasonably priced but it all adds up.


I had prepped the wheels over the last few evenings, they weren't in the best condition with a few gouges - the worst was filled with chemical metal - purely cosmetic.
So I browsed through my paint suppliers sample "chip books" and picked this colour. Iit is a Daihatsu red R48, it seemed to be close to what I remember and also to the decals on the tank - time will tell.
A quarter litre was enough (with some left over) applied over an aluminum preparation primer and finished off with two part lacquer.



I mentioned in another thread that my older brother had a one year old white AR80 back when i was 12. It was the first proper bike I got to ride and has me addicted to bikes ever since.
I will always remember the distinctive sound these little bikes make.
Unfortunately a car pulled across our path one morning and we ended up flying over the car and bouncing down the road. The bike was in a bad way. The front wheel was driven back beside the engine and the headstock collapsed back onto the engine. This bike was later rebuilt with a different frame, exhaust and complete front end and went on to cause more havoc around the area.

I went on to have my own black C7 AR80 for a time when I was 18 (I think) and between bigger bikes. It came home from the sellers with the engine in biscuit tins and the bike sticking out of the back of my mother's Fiesta. This one came home sticking out of the back of my wifes car, so there seems to be a pattern emerging with my AR80's.

I did some long trips on my first AR, including 170 mile each way trip to college,
I reckon I will have to do similar long distance trips on this one Very Happy
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mavesyn



Joined: 02 Jun 2009
Posts: 29
Location: staffordshire

PostPosted: Thu Feb 23, 2017 4:41 am    Post subject: Reply with quote

Great work, coming along nicely.
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Top-shaggy
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Joined: 05 Mar 2011
Posts: 1753
Location: Derbyshire

PostPosted: Thu Feb 23, 2017 5:49 am    Post subject: Reply with quote

Really enjoying this thread, particularly the ditty supporting the pics.
Oh and that little blue man (previously red) has a lot to answer for Rolling Eyes Wink
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