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Ghilli 09-20-2012 04:30 AM

Another R80g/s build, just slower
Hi Everyone

I've allready started the rebuild of my 1981 R80g/s, but with the amout of hours I've allready put in I feel I should share some of it, even if it is only to see my own photos.:cry

So here goes, this was my g/s in one piece 2 years back, it is in about 200 pieces right now.

I needed to replace the oil pump seal as it started to leak too much, wich I left as it is quite a big job. So in the process of removing the gearbox I decided I might as well do the whole thing (complete motorcycle I mean), and an hour after my well thought trough plan...

jellycow 09-20-2012 12:22 PM

Now, that's a way to enter Advrider!
Start looks good, can't wait to see the next steps.

Clay Spinner 09-20-2012 12:39 PM

Nice start! Take lots of photos... I@ll be doing the same thing soon enough.

scalpel 09-20-2012 10:10 PM

Ghilli fortunately you are an engineer!!!:D

Ghilli 09-21-2012 06:09 AM

Even though I am one I still needed to overcome my three fears:

-Removing the gearbox
-Disconnecting every single wire and cable
-Removing the barrels and pistons
-Welding to the frame

Ok four

Obviously I had to wash it in the kitchen.

scalpel 09-21-2012 07:20 AM

Cape Town
Ghilli daar is baie ouens in die Kaap wat jou kan help raam versterk. Goeie welders. There is a few guys in Cape Town that can help you with frame welding. With good experience. Send me a pm for more details. Stuur groete vir Koos. Send regards to your brother.:D

scalpel 09-21-2012 07:22 AM

See here

Local South African site.

Ghilli 09-25-2012 05:00 AM

Re-enforcing the frame looks really nice, but its too late for me now. I just fixed up the original frame and made a center stand out of three retired ones. Got that powder coated with a few other parts, and it came out really well, relatively cheap too.

This is the subframe with a piece torn out that I repaired.

I attached a new battery mount to the frame.

And repaired the damage the center stand made, those plugs are important.

Set up the frame to see if everything fits, before I need to bend any coated finished parts.

And here is my center stand made from old dead ones.

Ghilli 09-27-2012 06:11 AM

Drive shaft
Next up was the driveshaft, I took the original and a slightly less worn out shaft and swapped the bell housing. This was probably unnecessary, but the road going thrust adapter definitely had less wear than the one one the g/s.

The thrust adapter on the g/s lost that totally round profile and "sharpens" when it wears.

This called for some high tech tools, so I made me a high tech tool.:lol3

Ghilli 10-01-2012 05:08 AM

Not a lot of photos, but I wanted to try and do DIY nickel plating on all the bolts that are "special". All the other standard bolts will be replaced by new stainless steel bolts.

The plating came out very nice, I hope its durable as well. These are the plated rear shock bolts, the photobomb bolt on the left is a new stainless bolt, the unpolished plated bolts shines more than brand new bolts. I made those small spacers to reduce the hole size compared to the bolt, there was quite allot of play on the rear bolts.

This is a spacer inside the bolt hole on the swing arm.

Ghilli 10-01-2012 07:41 AM

Here's a cool photo for no reason whatsoever.

This actually gives you a good idea of areas to avoid when installing a wiring harness, there really isn't enough space to just route it anywhere.

Ghilli 10-02-2012 07:06 AM

Bad news time, I've seen this allot on the internot, now I have one as well.

The hub is out of its wear limit and looks like someone forced it off and started a nice crack, I was riding like this without knowing I was about 10 seconds away from death all the time.

Clay Spinner 10-02-2012 12:28 PM

Nice post... just a question... how does one measure the wear limit?

goatroper 10-02-2012 12:38 PM


Originally Posted by Ghilli (Post 19645809)

Obviously I had to wash it in the kitchen.

You know about the thrust washers on the crank, yes?

Ghilli 10-02-2012 01:44 PM


Originally Posted by Clay Spinner (Post 19729342)
Nice post... just a question... how does one measure the wear limit?

In the back of the manual it says that the max permitted wear on the drum is 201.5mm, that is the inner diameter of the hub which I measured with a large vernier. If you look closely you can see its a steel band that is cast inside the aluminium hub.

Only problem is, this is the data for a 4 bolt hub and not the older 3 bolt, not sure if it is the same for both models.

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