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PW 80 Performance

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Posted by: WhiteBros426

Hey Guyz....i picked up a 2003 Yamaha PW 80 for myself to use as a pitbike this year.....could someone please list all of the free performance mods along with the payed for modss? Also what performance gain you get from it? Any help would be great.....thanks alot Pete :flame:


Posted by: gwcrim

Click here----->PW80 Mods


Posted by: joereitman

48t rear sprocket, drilled out the welded in restricion in mouth of pipe, disabled autolube, leaned the needle 1 clip, longer rear shock, spacers in front fork to preload springs, more fork oil, Maxxis IT tires. I posted on the shock somewhere months ago. The bike wheelies in 2nd, will stand straight up in 1st


Posted by: WhiteBros426

What did you find had the best performance increase? should i start by taking out the welded in ristrictor in the pipe and the airbox snorkle? Thanks for the help Pete


Posted by: WhiteBros426

Can i use a dremel?


Posted by: WhiteBros426

Hey guyz....this is a list of what i have been thinking about doing to my 2003 Yamaha PW80R....

Intake:
-Twin Air Filter
-Remove Airbox Snorkel

Exhaust:
-Drill out stock restrictor in "expansion chamber"
-Remove Sparky
Then......
-FMF Fatty Pipe
-FMF Powercore2 Silencer

Tires:
-Michelin Starcross Mini Tires
-Tubes

Suspension:
-Minibike Heavy Front Fork Springs
-Heavy Weight Oil
-Works Suspension TT-R 90 Shock

Body:
Factory Effec Full Graphics and Trim Kit

Controls:
-Tag Metals Mini Works Bars (IF FITS)

Drive:
Renthal R1 "Works" 420 Chain
Any Front & Rear Sprockets

Motor: (Hopefull make em in the next couple months)
High Compression Head from Cycle Riders

Ill start with the intake tomorrow....and a new plug!
What do you think will have the biggest performance gain? (BESIDES HEAD) Please add on to the list as much as possible!!! Thankz Pete :thumb: :flame:


Posted by: joereitman

Instead of Dremel I used a large diameter bit in the drill press, then cleaned it up with a snap-on brand high speed rotary grinding die (DESIGNED FOR USE IN PNEUMATIC GRINDER) to clean it up. (sorry about caps- accident).


Posted by: WhiteBros426

What was the performance gain from it?


Posted by: joereitman

much better midrange. But the sprocket made just as much difference!


Posted by: KawieKX125

I just picked up a mint 86 big wheel 80 (like a pw80 with quad tires on it), and this thread is just the info I wanted. Thanks!


Posted by: WhiteBros426

VERY IMPORTANT: Everyone, DONT!!! remove the snorkel in the air box....i did it today and sucked dirt in and ****ed the bike up...luckly it pulled it self through after about an hour....we have 2 2003 Pw 80r's and on is completely stock, and the other is getting mods done......the gains were minimal and the bike revved a little faster, but its not worth the risk....especially riding in sand, mud and water....hope we can keep this thread going with more mods to do to the little Zinger Race Bike!! oh yeah, add these to the hop up list!

Body:
-Yamaha Racing Cleated Footpegs

Engine:
-Maxima 927 Castor Premix

something else i cant remember! DAMMIT!!!
anywayz ill talk to ya guyz tomorrow.....thanks Pete
Do regular MX grips (Renthals fit on the bike?) thanks again!


Posted by: christophe43

boyessen dual stage reeds,fatty pipe and silencer,move the needle,steel footpegs,scott grips,extended the rear shock(moves the seat up 4 inches),michelin tires,15w fork oil,uni sells air vents (filtered air vents)they are round w/foam filters in them-just drill a 1"hole in the airbox and slide them in, i have 2 in mine -9.99 for 6 thru dennis kirk.compart # 30-1545.the bike runs like a two stroke should,but it still isn't a kx65 and if i were to do anything else(high comp.piston)the suspension would need major attention. my 8 year old came off a xr50 and loves the pw80 it ought to last him a another year or so till i step him up to the 65.and yes regular size grips fit it


Posted by: KawieKX125

Boyesen does not make a reed for the pw80, what application did you use?


Posted by: WhiteBros426

:thumb: First off, boyesen does make reeds for the PW80.....its in the denniskirk catalog, i think? now for my question, how does your PW run from the bottom end....mine is pretty much stock and bogs....the bog was helped a little without the snorkel but it screwed my bike up so it deninently wasnt worth it! so, which mod that you did woke the bike up the most? what is the difference between stock pipe and the FMF....besides the silencer not being so restrictive....is the noise level raised alot? how hard was it to do the boyesen reeds? how much gain did it make? im sry about all the questions but im trying to find all the best mods to do, while keeping the bike bulletproof! i want to create the ultimate Pw80R Race Bike!!!!!! Thanks again for the help guyz, keep it coming!!


Posted by: christophe43

when i first got this bike i went down on the main jet from the 125 to a 120 and it helped clean up a lot of the mid range.the pipe extends the mid range and is extremely loud w/out the silencer w/the silencer its not much louder than stock.the reeds are a pain to install only because the 4 or 5 screws holding the plate down are nearly impossible to get to(need a longgg screwdriver and very short one,a socket adapter would probably help).reeds add to the snap off the bottom .if you are gonna keep it i would go with the pipe and silencer(sell them on e-bay when you get rid of it)for the most hit at once. Also dropping down one on the front sprocket will improve takeoff ,but hurt your topend.Like i posted before all this on the pw80 makes it perform the way it should have come from the factory- without hurting the reliability ,but it still isn't a rocket.the higher compression piston would probably do the trick but i'm not sure if its worth it.Hope this helps


Posted by: KawieKX125

WhiteBros, maybe they used to. I looked in DennisKirk as well as others and had my friend who works ast a Yamaha dealer call boyesen and then dont make one. They make a reed fo rthe 50 but not the 80.


Posted by: christophe43

read my lips boyesen reeds ,call Cycle Riders @(706)835-2453 and they will hook you up with go fast goodies for the pw80


Posted by: WhiteBros426

Here's my updated Upgrades List!

2003 PW 80R
- FMF Fatty Pipe
- FMF Power Core 2 Silencer
- Tag Metals T2 Mini Works Handlebars
- Tag Metals Big Bar Mounts
- Tag Metals Big Bar Pad
- Michelin Star Cross Mini Tires
- Twin Air Filter
- Boyesen Reeds
- Factory Effex Graphics & Seat Cover
- Renthal R1 Works 420 Chain
- Sun Star Front & Rear Sprockets
- Works Performance Rear Shock
- Mini Bike Stiff Fork
- Yamaha Steal Cleated Foot Pegs
- Renthal Grips

Im keeping this bike 4 ever.....i hate to sell bikes, just like my 426...that wont go untill the new bike arives! Anyways,
since im runing stock jetting, what will i need to do jetting wise for all these mods....richer/leaner u think? Id like to get more bottom end snap and midrange, cause that is what i use most while racing.....Any other tips would be great!!! Lata....P.S. what did you pay for your FMF pipe and silencer? CYCLE RIDERS? TTYL :flame:


Posted by: KawieKX125

How does everyone like the Works shock and the stiff fork springs? Also does anyone know if the PW pipe will fit a big wheel 80?


Posted by: christophe43

140 for the pipe and 70 for the silencer-before the pipe i was running the leaner jet (120) after i put the pipe back on i went back to the 125.I would rather run a little rich than risk running too lean :flame:


Posted by: WhiteBros426

yeah that sounds like the prices there giving me! the stock jet is 125? right? im going to order the Power Core 2 Silencer and a Twin Air Filter to start the mods.....is the Uni filter any better? and the silencer make a difference in performance and sound? im thinking about running Maxima 927 Castor Oil (Premix)....i always run Amsoil Injector Oil (Synthetic) or Amsoil 100:1 Oil in premix bikes but fell in love with the smell of the 927 .......what do u think about that? Maybe some renthal half waffles for looks! thanks guyz.....talk to you tomorrow!


Posted by: christophe43

yes 125 is stock and the bike did feel a little faster with the silencer,but it may have just been the smoother exhaust note-i'm not sure. i still run injected since this is my sons and i want to keep it as easy as possible to get ready to go places(other bikes a 4 stroke).when i get some time i am going to add a spacer to the fork springs to try and stiffen them up a little along with the shock spring.


Posted by: christophe43

hey whitebros -how does the modified pw80 compre to the stock one?and about the filters the only ones i have tried are the MOOSE brand.They are better than stock,but nothing like the qaulity of a filter for a bigger mx bike.


Posted by: WhiteBros426

Its still in the mod. stage....but it is gonna smoke the stock one....the stock one will be getting mods done also, when im done with this one.....it cool to be able to compare the bikes one on one! im ordering the FMF Silencer today and a Twin Air Filter.....what FMF Silencer do you have? PC2 or TC2? is there any difference in lenght between the two? cause i would rather have a shorter on cause it looks more 2-stroke like and it will have a better chance when bailing in the air! ill get back to you guyz sooon....later Pete and the silencer sounds more 2-stroke like, right? like a zing zing sound vs. the scooter sound! :flame: ok gotta go


Posted by: christophe43

i got the PC2-do not know the lenght on the other ,but I don't see how it could possibly be any shorter.Sounds good w/ it and it even looks good.If you talked to the guys at cycle riders did they mention when they were gonna get the high comp.piston?


Posted by: WhiteBros426

I talked to em' and they said they will make a high compression head, not piston....WISECO makes oversized pistons for the little Zinger! they will take your head and do **** to it for more compression for about 75-80$ i think.....ill talk to ya lata!


Posted by: RHarper

Quote:
Originally Posted by joereitman
48t rear sprocket, drilled out the welded in restricion in mouth of pipe, disabled autolube, leaned the needle 1 clip, longer rear shock, spacers in front fork to preload springs, more fork oil, Maxxis IT tires. I posted on the shock somewhere months ago. The bike wheelies in 2nd, will stand straight up in 1st


Nothing like blowing the dust off an old post. I've read several times about drilling out the welded in restriction in the mouth of the pipe.

When someone says mouth, are they talking about where the pipe meets the head?

When I took out the removable restrictor in the pipe, the pipe seemed to condence right back down to the same diameter that the restrictor condenced it to before it was removed. There seems to be two round inserts that lead all the way into the pipe itself. Are they the welded in restrictors? They look like they come out. I hope this makes sence.

Growing up my father always wrenched on my bikes. So I'm just learning.

TIA


Posted by: h2otech1

Finally, I have found some info on the BW/PW performance upgrades. After years of teaching my kids to ride on our BW80, the last two years the bike has been storing dust since my youngest moved to his new RM85. For fun, he wanted to rebuild the bike, ground up. We are about 75% complete. Here's what's happend so far:

Purchased KTM65 stock pipe from e**Y. Cut each bend and refabed the entire pipe to match the fit of the bike. Am using the stock silencer, but this may change after its fired. The fatty chamber looks awesome, but has yet to be tested.

Complete sandblasting on all parts with new 05' Yamaha color scheme of silver / blue.

PRO Taper XR-50 hop-up bars, look excellent. Polished most every aluminum part on the bike including front fork tubes, caps and risers. Also used new PW80 dust seals on forks rather than the old fork boots, much cleaner look.

Have seen a 1' riser on e**Y to fit on the shock for higher lift. Maybe an option, but like the idea of drilling another hole for shock remount. Saves about $30 bones.

After the bike is back together, I will run motor stock w/pipe to troubleshoot performance. Raising carb needle also seems to be a good option. Changes of sprockets?? Maybe.

Completely removed air box (POS design), keep carb snorkel and are using a 1" UNI filter. More airflow should equal better breathing plus looks alot cleaner as well.

Wish list after firing, change piston to 0.40 over stock.

Will post further as time progresses. Thanks to all for the good tips!!!


Posted by: NewbieRider80

You guys have talked about drilling something out in the pipe to make it less restrictive? could somebody that knows wut they are doing explain how to do this in detail please?


Posted by: alcoolj

any chance of some pics of this restricter in the pipe i dont want to go hacking away without knowing what im doing and great forum hope i can add something useful


Posted by: abbuB

Hey yall! Great post by the way. How about some pics of your mods for those of use who are visual learners? And new to modding bikes. Thanks!!!!


Posted by: abuse

Yeah, can someone get some pics on what to cut off? I cut the cone off of the exhaust, is that it? Maybe some links to the mods of where you got them from? I just got this bike and I am wanting to do some mods to mine as well. Thanks!


Posted by: sporty hog

Well, my son and I have changed his PW a bit. We lifted the back with a simple shock extender. The front was raised by adapting a YZ 80 front end. That bolts on but you have got to drill the front hub assy for the larger axle. Not too hard. then the full FMF system allows it to spit out the bad stuff that the Boyesen power reeds pump in. Shaving the head brought the compression up a bit. Removing every other ball in the clutch raised the rpm grab. Pirelli tires were our choice. Fly bars, Factory Effects seat cover, YZ front plastics and custom graphics give it some eyeball. We are playing with carb mods now but this little PW stands for attention, and gets it.


Posted by: brax

what year yz80 front end fits? thanks


Posted by: paulopw80

If you remove the snorkel,it f***īs the bike?
But if you have carefull and donīt let mud sand or water to get in to the pw 80



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