Alright guys here we have a 2001 XR 80 This is the dirt bike that my girlfriend Ellie bought for herself, and we got to do some fixing on it so the first thing it runs like crap carburetor needs to be rebuilt and Besides that we could just kind of sloppy here That's not good at all. And it just needs a general cleanup. So Excited to get started. Yes. Alright, let's get after it I'm going to show you guys how bad this thing runs carburetor is definitely in need of some attention Alright, so the first thing we're gonna do here is pull off some of the plastics seat and gas tank clean it up and See, what's up with that carburetor? Slide it back a little bit. There you go Just gonna pull straight out right here How dirty it is underneath the tank so Yeah, that's why we're washing it up So next up is gas tank. Oh, yeah a little strap on the back, right? Yep, pull that off My bar height is ugly hold on officer Time for a new one All right, so we're pretty much bare Down to where we can get to a lot of that dirt and she is gonna give it pressure wash So next up we are gonna pull the carburetor off here go through it and rebuild it and get this thing around and Prime We have a carburetor rebuild kit that Rocky Mountain sent over This setup right here. So that should do the trick There you go Good work Wrench on that thing there Pull the whole thing off. That is the carburetor. Let's go through and fix it up The bulb just slides right off of there so that's where all the Jets are at and Probably some plugged up jets in there. That's why it ran so crappy Those are the floats looks like we've got yep new needle for that Just read that out of there So that's the main jet So once we slops the new jets in this thing new seals and all that should be running really good. Can you pilot? Just gonna rip. Yeah good thing they gave us a new one. Okay a Lot of times these seals don't really want to stay in place especially a new seal So, you know it grease on it, and I should help it We are working on the fuel screw here they provided a new one and a new Spring and during I believe so Those will go ahead and replace that There's gonna be a little spring in there to It there we go Mm-hmm What we're gonna do is thread it all the way in and then back it out two turns Usually where it should be. You have a good running bike, babe Get that crust to seal out of there So right here I'm gonna do is actually I'll hold those pieces or we got to pull it apart So compress that spring? And there's gonna be a little cable that pops out the end of it Pull that cable out of the slot And then pull spring off and that is the seal we're replacing Needle we're gonna place that yep, push it up a little clip that Just goes inside of there and it lays flat I guess the clip hold it in so Now what you got to do is compress the spring like This yeah pull the cable out Nice having little fingers, isn't that so hard for me to do that? So it's got to go like in the slot so you gotta like twists it around until it goes all the way down All right, so you've got the carburetor back on but before we fire it up and test it out We've got a few more things to bolt up here. So we have a plus cable an air filter New grips and of course any bar pad? All right. Let's pop them on. All right First thing is gonna be the clutch cable. I'll have you open that up All right. So the old one we're gonna pull off here Let's get an exposed Pull on the lever Pull the cable out That and through the slot Just like that and then it pops out the bottom of the lever here And you can see why we're replacing this cable it's starting to fray right here right as it goes into the housing so Fresh cable will make this clutch a lot easier to use. Okay, so we're going to slide the cable out Here on the handlebars and then next down At the engine down So before I put any cable on even if it's a new one, I like to score some lube into it So I like to use this motion Pro cable Luber This goes right onto the end of the cable and give you a little demonstration of how this works So you can see now we have a like a complete sealed housing here and Lube, it just goes in right at the end of the tool here So once I squirted it in I'm going to push this plunger in and that'll force all the lube through the cable Couple squirts Pushing the plunger force it all the way through And that's all you got to do. Now. We have a cable works. Super smooth. Yep, just round it up through there Looks like we had it before There sucks right on to that arm there so a new cable should be pretty easy to hook up perfect. There you go Yep Perfect, so the last thing we need to do is set the clutch cable free play and how we do that is by adjusting this little straight here and So we're gonna go out We've got too much play right now Screw that out a few turns and try it again So basically she's pulling the cable and the lever apart from each other. What a little bit. Yeah. There you go so that had about Well, maybe quarter inch of slack there So just a little bit more. So there's about the width of a the width of a coin Yeah, there we go. So screw that all the way into the lever. There you go. That'll walk the adjustment in place Perfect so that is it for the clutch cable if you one more thing here down at the bottom we have These two adjustment nuts. So if you can't get enough slack up at the top try adjusting These two nuts at the bottom clutch cable is done. What's up next? Alright that's probably a good idea to put on there because there's no bar pad on there right now and Sweet and Now we've got a grip Open those things up This is the fun part. It's fun taking off the grips and putting new grips on with my method at least Blow air inside the grip it expands and slides off the bar pretty simple concept Time for the rogue ribs. I'm actually curious to see how these ones our tusk never never use test ones before so try them out All right It's like that grips in place pretty good. And what's up next? All right, we're gonna replace the air filter with this test air filters See how that old one looks in there. Probably really gross, huh? Nasty Can't believe Run it like that. Yeah rip that thing off and throw it away No, probably not even worth cleaning that one Okay, you should probably clean up that cage and some of the air box they're just gonna use some See print cleaner on that that should do the trick And of course air filters need some oil, so we're just using this Maxima bad one oil Hose it down pretty good all one solid color All right veg we go back on the bike Alright the last thing we're going to be working on here I want you to get it because you ended up doing the bar pad the grips and a clutch cable So what are we working on here? So we're gonna do that linkage bearing kit and rocky mountain sent that over Yeah, why are we doing that and we're doing that because it's a little bit All right, let's get to it all right, let's do it Jack this thing up on the scissor left. That way we can get to the linkage down here so this whole kit replaces the nylon bushings that go in there and as you can see I think we showed this earlier, but this linkage is really really sloppy Yeah, all that slop right? There is not supposed to be there. So this kit will fix that up So linkage is this piece right here? We've got the dog bone and then the triangle So just got four bolts. We need a full lock here For this last bolt to the dog bone you can see it hits the foot peg mount So we are gonna have to pull this off Hunkajunk Wow strong battery Now this bolt should slide right out of there, there we go Triangle piece Of them Now it's up to me to replace these bushings and I'm gonna let her go work on her homework So here's everything that was in the kit. We've got the pins Bushings all four of them all of the dust caps seals for the Lower shock bearing so a pretty complete kit if you ask me and we're going to be using the vise over here To be pushing all of these old bushings out Of the linkage and we'll be using the vise to pop in the new bushings as well so it's pretty simple to pop off the old dust caps and bushings the Elvis slide right out They're super crusty. All these ones have quite a bit of dirt packed in them So you can see this bushing and pan are pretty loose and that was the reason for all the slop in the linkage This bushing right here. And then I believe this one has a little bit of play in it as well Not too bad That one's all done And this pin spins gonna be a little bit crusty. I Have to pound that one out All right from the looks of it these bushings should push right out a dog bone however has Two separate bushings one on each side and it sits in a step so I can't push this Bushing all the way through the linkage to remove it. I'll have to use a blind bearing puller To get a hold of this bushing and yank it out this way now to push the bushings out We're going to use a combination of sockets here So we've got a socket that fits with the diameter of the bushing and then another socket that fits over the bushing So we're gonna put it in the vise just like that Clamp it down and it'll push that bushing right out So these sockets aren't quite deep enough for the bushing to push all the way out So I'm just gonna have to hit it out of angle real quick here just for the last little bit These bushings are plastic So they pop out pretty easily now If they were metal and pressed in I definitely wouldn't go at an angle there move on to the next bearing in the next bushing Yeah, so that's all it takes an hour for the last bushing there's a seal on either side Pop that out of there Man, this link is just super crusty I'm glad we're replacing all this stuff and there is gonna be a little Like a slimmer bushing inside of there. You can barely tell that bushing is still in there It's really dirty and worn out but we're gonna have to find a way to push it out of there and replace it so right here, I've got the new bushing and I'm gonna size it up with a socket that way I know which size to use to push the old one out All right, so this last bushing is being a bit of a pain to get out This socket is really hard to get perfectly centered on that bushing you can see how thin the wall is on that bushing and I've tried heat heating it up using a socket with a lip but seems like this one just You know expands the bushing and gets stuck in a place even more So what I resorted to is Using a saw I'm just gonna cut through that bushing that'll release the tension on it I'll be able to peel it out of there and press the new bushing into place So this bushing is so rusted and stuck in a place not even heat We'll break it loose so I'm literally just going to peel this bushing out of there Sweet there we go making that little cut definitely loosened up the tension on it and It broke loose. So to pull the bushings out of the dog bone. What we have here is a blind bearing puller this is like a slide hammer of sorts and I'm gonna find the Collar or the adapter that fits into that bushing looks like this one will work pretty good So how this works is there's a lip inside of there when I tighten these two pieces against each other It's gonna expand that lip and then I'm gonna connect the slide hammer to this pop it right out should be pretty painless I'm gonna thread the slide hammer into collar give it a few taps. And this thing should pop right out. I Can't believe how stubborn this thing is what might be happening is this Adapter or the collar is too tight, and it's actually like lodging that bushing into place once again, these things are plastic, so They flex pretty easily. Let's try this out There we go So lesson learned if you guys are going to be using a blind bearing puller To pull out plastic bushings. You definitely don't want to have these things tightened against each other really tight or else it's gonna expand that bushing and It's gonna be stuck inside the linkage. So just keep that in mind I think I'm just gonna tighten these ones by hand just like that I've got all the old bushings pressed out. The next step is to clean this stuff up and Press in the new ones while I have this stuff apart and all the bushings out Figured I might as well give us some fresh paint. So I've been using the rougher pad It's like a scotch-brite pad here on the buffer just to knock off some of this rust and then I'm gonna spray it with Just some spray paint. Wish I have the time to go ahead and powder coat all this stuff, but You know what? We're just trying to make this bike functional. So spray paint will do So I squirted some pain on the linkage doesn't look too bad it's a nice little gunmetal gray So I'm gonna start with a dog bone piece. There's the new bushings make sure I have a nice VAT coat of grease on everything and The new bushings are plastic as well or some sort of kind of softer material So I'm gonna use a set of soft jaws like jaw protectors To protect the linkage and bushings from any damage During installation and for grease I will be using this Maxima waterproof stuff Never hurts to be a little bit generous with the grease here Damn not the fresh paint comment if you know where that's from that dude is freaking hilarious Looks like it's all the way in it's gonna grease up the other side and pop this one in as well Bushings are in just gonna pack a bunch of grease inside of here and Then I can pop in a spacer and put on the dust caps So to protect these bearings or these bushings I keep calling them bearings they're not actually bearings but to protect them from wearing out definitely want to have some grease in there and another factor that leads to them wearing out is And this isn't necessarily a perk and motocross bike so you don't want to be beating on it too hard and taking it off of big jumps and stuff so not enough grease and just general abuse is what leads to These bushings wearing out and when you're pushing these bushings make sure you don't clamp the Vice down really tight or else it'll actually squish the Bushing inside of here and the pin won't fit as well Please don't ask me how I figured that one out. And the last thing we've got for this piece is a couple of dust caps Sweet now, we have a linkage that works pretty smoothly. I'm gonna move on to the triangle piece now Got the linkage back in order Looking prime time to get it bolted up on the bike since the majority of these linkage bolts have rust or corrosion I will be using some Anti-seize lubricant to prevent them from rusting more in the future Now in order to get this rear end up high enough to get the linkage in I'm just gonna use a tie strap To kind of hold it into position Right there should work pretty good Now the last thing we'll need to do is work these bolts For the larger ones, I'm gonna go 25 foot-pounds and the lower shock bolt. I'm going to torque to 20 Man that is looking fresh every minute. This bike is looking better so now we're gonna do a little test on it and see if there's any slop in the linkage like we had previously so I'm gonna pull up and down on the back wheel and Hold the back of the bike down like the suffering part of the bike as I'm doing this See if I can get any movement out of it Nope well, there's a little bit of play there maybe like an eighth inch but that's a heck of a lot better than the Probably inch we had before it so that's it for the linkage the next thing we're gonna be doing is bolting up the gas tank and plastics and Seeing if this guy runs. Oh, I can't forget to pull up the foot peg She's back. I was studying You know Good yeah So what do you tell him what you're going to school for? I'm going to school for dental hygiene. So pretty soon Pretty soon one year. I'll be a dental hygienist. Yeah Boom. All right, let's get this thing back together and see if it runs Pop that thing mom we got old gas in there Thing's been sitting in the corner for a few months Slop down shrouds back. Oh, look at this side Crammed in the hole Slap that puppy on and I think we'll be ready to fire this thing up. Yeah, we're gonna replace that seat cover all torn up You excited to hear this So as you guys heard the bikes still running pretty rough and a hundred percent sure I got that carburetor Completely clean. There's no plug jets No plugged holes anywhere. So what I'm thinking is going on is This thing has aftermarket exhaust on it. It's got bbr about VBR pipe and what it sounds like is It's running a little bit lean. So I'm thinking it's not jetted properly for that pipe so I'm gonna pull the carburetor back off check what sizes are in there and then bump up the main a size and Possibly the pilot as well All right, I've got the Jets out let's take a look at what sizes we have here. So this one is the pilot jet It'll have a number stamped on the side of it So right there, it's a 35 and this is the main jet this jet has a much bigger hole So it should be a bigger number. This one is a 95 so bbr recommends a 105 main and 38 pilot for this pipe. All right, so I found a 105 main and a 38 pilot But I'm just gonna throw the 105 main in and see if that makes a difference I don't want to make too many changes at once. I Just noticed these hoses are getting a little bit weathered so I am going to replace them with Some of this red in the Hilo hose shoot that a little bit of touch this bike Now, let's see if it runs any better with that 38 Pilot So she runs really good down low doesn't bog anymore, there's just a little bit of hesitation like mid-range You can hear it. It'll pull and that will drop off and that'll pull hard again. So I'm thinking that I'll need to adjust The needle here I'm gonna pull up the slide. It feels like It's a little bit too rich on the mid-range. So I'm gonna drop that kneel down by one clip So it looks like that clip is in the middle position I'm gonna bring it up one notch and That'll lean it out just a little bit and I think it'll fix that little hesitation issue Yeah Good So I think we got to run pretty good now and when I was out ripping It seemed like the linkage was nice and tight. So the bike is pretty good. Mechanically, I added one more thing here It's gonna show you guys some more red Fuel line or red hoses found some more of this stuff in the cabinet It's from the helo, and I'll actually link it down below for you guys. This is the best Colored fuel line. I found doesn't deteriorate and crack like most from here on out What we're gonna do is a little more fixing things like tires chain sprockets Seat covers torn some graphics got some other cool ideas for it Basically just gonna do a little mini build series so that way Haley has something cool to ride So why don't you guys put it down below in the comments section what you want to see done to this bike? So basically all the parts going on this little X RIT are from Rocky Mountain There are a really good resource for aftermarket parts OEM stuff Riding gear you name it? They have it there pretty much where I get all of the parts for my bikes So that's gonna be it for this video I hope you guys enjoyed it or learned a thing or two If you did make sure you share it with your writing friends and stay tuned the next video coming out with this little XR 80 Thanks for watching everyone
