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Discussion Starter #1 (Edited)
bw sideshot.JPG DSCF0422.JPG DSCF0420.JPG Here's my BW80. Mods include: aluminum wheels, cut and welded top clamp, heavy fork springs(for pw80 or ttr90), KLX110 style tall bars w/ motion pro throttle and push button kill switch, KLX110 extended front brake cable (fits perfect) modified airbox, Boyesen reeds, milled head 1mm, eliminate oil injector, steel pw80 pegs, lowered footpeg bracket, fastace reservoir shock w/550 lb. spring from ebay, chain roller and chain guide, dual mufflers, PW80 aluminum kickstarter , taper steering bearings. A great bike for the campsite, easy to ride for kids and adults.....
 

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Nice. I had one, wish I hadn't sold it. There's not many around. Milling the head does alot & a pw fmf pipe will fit. You can also remove some of the clutch balls for a higher catch point.
 

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Here's my BW80. Mods include: aluminum wheels, gull winged top clamp, heavy fork springs, tall bars w/ motion pro throttle and push button kill switch, modified airbox, eliminate oil injector, ebay pw80 pegs, fastace reservoir shock w/550 lb. spring, chain roller and chain guide, dual exhaust (why not?) cut down kick starter, taper steering bearings. A great bike for the campsite, easy to ride for kids and adults.....
Dude, that thing is cool! I like those aluminum wheels too!
 

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Discussion Starter #5 (Edited)
I was wondering about the FMF pipe, did you have one on a BW80? I did the clutch ball removal but have left the motor stock other than Boyesen reeds and 1mm off the head. How much did you mill off the head? Thanks guys...
 

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Fmf pipe bolts right on. 1mm I believe off the head. they're like 6 to 1 stock so it's really low. Porting is supposed to do major things on that motor too. I didn't have mine done.
 

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Discussion Starter #7 (Edited)
Good news about the pipe. My only worry with boosting the power is the clutch, it has new plates and fewer weights but is still wimpy.....
 

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The head is a good bit cheaper to do than the pipe. I pulled the stock end cap out & cut the spark arrestor out & put the tip back in. I also was running a pod filter with the jet to match. Like I said, wish I hadn't sold it.
 

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Discussion Starter #9 (Edited)
Yeah the pipe is expensive. I did remove the little bullet shaped piece from the front of the spark arrester and re-installed it. The reeds, air cleaner mods and spark arrestor mods all helped the power. Thanks for your input "46"
 

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Lot of potential. I like it
 

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That is really nice, I like the wheels. I have two of them myself, the one with no stickers is an '86 and has a chineese top end, I did some hillbilly porting with my dremel, air box mod and twin air filter and a 13t front sprocket, and no muffler or oil injection right now. It is a little rough looking, it was a mess when I bought it and I sanded the heck out of it and rattle canned it, but it is pretty stong. The other one is a '90, has airbox mod and spark arrestor out, runs fine but is no match for the other one. I moved the needle up one on both of them, it helped immensly as they are super rich stock. probably going to keep it closer to stock since it is really clean, the other one is my guinea pig. Going to do the head next... 2012-04-01_13-35-27_683.jpg 1st BW.jpg
 

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Ive been keeping my eyes open for one of these. People either want crazy money or they are beat to nothing....and they still want crazy money haha
 

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Yeah, the prices are stupid. I paid $225 for the first one, but it didn't have a seat, muffler and the top end was apart in a box. The second one was complete and just needed cleaned up, I had an add looking for parts on CL and the guy sold me the whole bike for $250. People on ebay want a fortune for most parts, except for the chineese top ends, but if you are persistent there are good deals and many of the PW parts are interchangeable. There is one on CL in Denver right now in about the same shape as my first one for $500...
 

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Discussion Starter #15 (Edited)
$250 for the 90!, sweet deal. Yeah, most of these are beat or broken. Finding a good one is tough since they didn't sell alot of them. I've always said "it's not what it cost, but what it's worth". Knowing the value of anything you buy is key. If you have to pay more for a good one, you'll get your money back if you take care of it. As for the 10" front rim, it's for a Yamaha quad. It has the same hole spacing and is heavy duty. It needs some spacers between the hub and rim to get it centered between the forks but looks clean and works great. Also tubeless which is a plus. The rear rim is 8" instead of the stock 7". I found it at Chaparral with a centered 3 hole mounting flange. I had to custom cut out the mounting flange to the same dimensions as the stock hub to get it to fit. That was a pain but there is no other option I know of to get an aluminum rear wheel. Lots of tire options in 8" and it's also tubeless.
 

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The wheels look awesome on there, and like you said, way more tire options. The deal I got on the '90 was great, the guy had it chained up in a parking garage in some condos in Denver, I didn't even try to talk him down. I paid almost that much for the other one in pieces. I do like having the beater, I want to try milling the head myself and get an FMF on it and see how it does, eventually I am going to use the original cylinder and put a Wiseco piston in it as well (.080" since it is really worn out), remove half of the balls in the clutch and go from there, I like to go to the dunes atv'ing and I like riding it from camp to camp.
 

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you wouldn't have your old Yamaha part numbers for those wheels would ya? We have a stall with 6 fully restored bw80's. Have an annual big wheel race / party too. I would love to have a set of those wheels! Plus we are out of rear tire options, (we bought the last 3 rears the factory still had in stock last year). Thanks!
 

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Just picked up a clean bw80 and ready to get this thing able to ride like a 125 with out boring...
Do we have a forum just to these little bw80s? I know the atc 70s are very popular.
 

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Discussion Starter #19
They are basically a PW80 so engine mods would be the same. Forks are the same other than the clamps. They make heavy springs for them. I can't say enough good things about how well the Fastace reservoir shock works on this bike. The 550 lb spring for adults is perfect. The geometry of the swingarm allows the spring to work right. PWonly.com has some nice items (look under PW80) but they always seem to be out of stock. Do some searches on PW80's, there's info out there on upgrades....
 

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Very cool bike! I always wanted a big BW, I think they made a 350 also, right? That would be a great candidate for one of my spare 490 motors!

But it's good to know that the 80 motor has enough power to be fun and pull around those big heavy wheels. Now I want one! That motor has a ton of potential. You could open up the exhaust port to 70% of bore and open up the transfers. If you have the tools, all it costs is time and a gasket set.
 
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