Page 1 of 4 1 2 3 ... LastLast
Results 1 to 15 of 50

Thread: 1983 R80ST Rebuild For Charity Project Journal

  1. #1
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543

    1983 R80ST Rebuild For Charity Project Journal

    I have just started a new project at "Brook's Airhead Garage", a rebuild of a 1983 R80ST for charity. When I complete the project I will auction the bike and all proceeds will go to a charity, The Motorcycle Relief Project, that uses motorcycle rides to help military and first responders cope with PTSD.

    This is what I am starting with.

    1983 R80ST As Delivered To Brook's Airhead Garage
    1983 R80ST As Delivered To Brook's Airhead Garage

    And this is what my target is when I'm done.

    The Target For My Rebuild, R80ST In Metallic Silver Livery
    The Target For My Rebuild, R80ST In Metallic Silver Livery

    I contacted Euro MotoElectrics about this project and they have generously offered to supply parts from their inventory at no charge as they have been supporting the Motorcycle Relief Project. That is awesome generosity for a worthy cause.

    I have posted the initial pre-build inspection and high level project plan on my website along with a short YouTube video of the inspection on my YouTube channel, "Brook's Airhead Garage".






    YouTube Video: 1983 BMW R80ST Pre-build Inspection

    I also started the project index page that contains links to all the documentation I publish on the project. It includes some background on the provenance of this bike. I update this page as I post new documents about my work.


    I hope this is helpful.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  2. #2
    Registered User STEVENRANKIN's Avatar
    Join Date
    Dec 2006
    Location
    Spencerport, NY
    Posts
    1,426

    Looking forward

    Well Brook, like all of your projects, I look forward to following the progress and viewing/reading the excellent videos and reports you produce on the side. If I were closer, I would offer a hand to help. St.

  3. #3
    Registered User slowpokepete's Avatar
    Join Date
    Aug 2020
    Location
    Hillsdale, NY
    Posts
    202
    Very cool, I have an '84 ST myself.

    Good luck with the project!

    SPP
    Member # 222067

  4. #4
    Back in the saddle again mikegalbicka's Avatar
    Join Date
    Aug 2014
    Location
    Lakeland,FL
    Posts
    2,246
    What a neat project for a worthy cause. Best of luck. Will be following your progress with eager anticipation of the final result.

  5. #5
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543

    Smile 1983 R80ST Remove Electrical System

    This bike is a "project bike" so some of the electrical components are missing. That makes it quicker to remove the electrical system. :-)

    1983 R80ST As Delivered To Brook's Airhead Garage
    1983 R80ST As Delivered To Brook's Airhead Garage

    I show how I removed the electrical system in this document.

    I also made a short video overview of the R80ST electrical system



    VIDEO: 1983 BMW R80ST Electrical System Overview

    Here is the main wiring harness I removed after I disconnected it from the electrical components and various sub-harnesses that I also removed.

    Main Wiring Harness After Removing Under The Gas Tank Electrical Components
    Main Wiring Harness After Removing Under The Gas Tank Electrical Components

    Main Wiring Harness Removed
    Main Wiring Harness Removed

    It's good to get back into the swing of things on another rebuild project.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  6. #6
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543

    1983 R80ST Remove Center Stand, Crash Bars and Side Stand

    I'm making progress on the disassembly of this project bike. That said, a lot was already removed, so this one isn't taking me as long. :-)

    As Delivered To Brook's Airhead Garage With Some Parts Missing
    As Delivered To Brook's Airhead Garage With Some Parts Missing

    As Delivered To Brook's Airhead Garage
    As Delivered To Brook's Airhead Garage

    The left crash bar includes a bracket for the side stand instead of mounting it on a bracket that's part of the front engine mount stud.

    Left Crash Bar With Side Stand
    Left Crash Bar With Side Stand

    Side Stand Mounting Detail In Left Crash Bar
    Side Stand Mounting Detail In Left Crash Bar

    Here's a link to the documentation of how I did this work.

     
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  7. #7
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543

    1983 R80ST Remove Front Suspension

    After I removed the wheels and the handlebar, I'm ready to remove the front suspension: the front forks, the steering stem nut, top plate, steering head bearings pre-load adjuster nut and the steering stem with the attached lower triple clamp.

    Bike After Wheels Removed And Ready To Remove The Front Suspension
    Bike After Wheels Removed And Ready To Remove The Front Suspension

    You can read about how I do this work here:

    And here is a short YouTube video that summarizes how I do this work.



    VIDEO: 1983 BMW R80ST Charity Build: Remove Front Suspension

    Here's the bike after I removed the front suspension.

    Bike After Wheels Removed And Ready To Remove The Front Suspension
    Bike After Wheels Removed And Ready To Remove The Front Suspension
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  8. #8
    Registered User STEVENRANKIN's Avatar
    Join Date
    Dec 2006
    Location
    Spencerport, NY
    Posts
    1,426

    Work

    LOL, Brook, I have always found removing things to be a cake walk. It is the reverse that caused me on my RT project last winter to refer numerous times to your videos on your RT project. St.

  9. #9
    Registered User slowpokepete's Avatar
    Join Date
    Aug 2020
    Location
    Hillsdale, NY
    Posts
    202
    Really enjoy these...thanks and keep 'em coming.

    SPP
    Member # 222067

  10. #10
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543

    1983 R80ST Remove Rear Drive, Swing Arm, Monoshock

    After completing this work, most of the disassembly down to the frame is complete as I also removed the rear sub-frame and muffler that is attached to it.

    Rear Drive, Swing Arm & Rear Monoshock
    Rear Drive, Swing Arm & Rear Monoshock

    Rear Sub-Frame Removed
    Rear Sub-Frame Removed

    Muffler Removed
    Muffler Removed

    Down To The Air Box, Transmission, Engine and Frame
    Down To The Air Box, Transmission, Engine and Frame

    All I have left to do is remove the air box, transmission and the engine from the frame.

    You can read about how I do this work and watch a short YouTube video summarizing the work here.



    VIDEO: 1983 BMW R80ST Remove Rear Drive, Swing Arm & Monoshock
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  11. #11
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543

    1983 R80ST Remove Air Box and Pulse Air System

    The air box is secured to the top of the transmission. Inside are components for the crankcase rebreather system and for the Pulse Air System which is a passive system designed to reduce emissions to meet the US standards in the early to mid-1980's.

    Air Box With Pulse Air And Crankcase Rebreather Components-And Some Leaves
    Air Box With Pulse Air And Crankcase Rebreather Components-And Some Leaves

    NOTE:
    The picture was taken when I first saw the bike and the air box cover was missing. Leaves are not part of the crankcase rebreather or pulse air system inside the air box. :-)

    The Pulse Air System is a passive system with no active motors or moving parts. It sucks filtered air into the exhaust manifold in the heads to help burn any gasoline and to ensure CO emissions are converted to CO2. That said, according to Bob Fleischer's information on the Pulse Air system, this increases the exhaust gas temperature and likely exacerbates wear of the valves and seats and could contribute to warped heads. The original valves and seats in 1983 had problems with valve recession due to excessive wear from the metallurgy BMW used to try and compensate for unleaded fuel.

    For these reasons, I'm going to update the Pulse Air system and modify the air box so the valve train stays nice and cool. I will purchase a smog kit from Rubber Chicken Racing Garage that has all the parts needed to complete this upgrade.

    Here is the documentation of how I do this work and a short YouTube video summarizing the procedure.



    VIDEO: 1983 BMW R80ST Remove Air Box & Pulse Air System

    I'm ready to remove the transmission and the engine from the frame.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  12. #12
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543

    1983 R80ST Remove Transmission

    The transmission on this 1983 R80ST is serial number Z 078854. According to Robert Fleischer's article on transmissions, the range of transmission serial numbers in 1983 was from Z 074700 to Z 084299, so mine is the original transmission as it is within the range for 1983.

    Transmission Serial Number Z 078854
    Transmission Serial Number Z 078854

    I removed the transmission after removing the battery and battery box, the rear drive, swing arm and monoshock, and the air box and the pulse air and crankcase rebreather components.

    Battery Box Removed
    Battery Box Removed

    Rear Drive, Monoshock & Swing Arm Removed
    Rear Drive, Monoshock & Swing Arm Removed

    Air Box With Pulse Air And Crankcase Rebreather Components
    Air Box With Pulse Air And Crankcase Rebreather Components

    Air Box Removed
    Air Box Removed

    I found water in the transmission gear lube. The speedometer cable was missing and the hole in the bushing for the cable was plugged with some cloth. Since the bike was outside for awhile, water entered the transmission through the hole in the bushing.

    Transmission Has Water In It :-(
    Transmission Has Water In It :-(

    Here is the documentation of how I do this work along with a short YouTube video summarizing the procedure.



    VIDEO: 1983 R80ST Remove Transmission

    I am ready to remove the engine. Before I do that I will remove the top end of the engine to reduce the weight.

    Transmission Removed
    Transmission Removed
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  13. #13
    Registered User
    Join Date
    Jan 2018
    Location
    longmont Colorado
    Posts
    194
    Nice Work Brooks !

    I can't tell you how much I appreciate your articles... and have been using your /5 articles for 4 years now on my project.
    thank you
    brant

  14. #14
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543
    Quote Originally Posted by brant914 View Post
    Nice Work Brooks !

    I can't tell you how much I appreciate your articles... and have been using your /5 articles for 4 years now on my project.
    thank you
    brant
    Thank you Brant. You are the reason I take the time to document my projects. The more airheads flying down the road, the happier the universe will be.

    Best.
    Brook.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  15. #15
    B Reams brook.reams's Avatar
    Join Date
    Jan 2007
    Location
    Arvada, Colorado
    Posts
    543

    1983 R80ST Remove Top End & Cam Followers

    In preparation for removing the engine from the frame, I remove the top end (valve covers, heads, cylinders, wrist pin, cylinders) to reduce the weight. Although not part of the engine top end, I also removed and inspected the cam followers as it is convenient to do that now.

    Ready To Remove Top End
    Ready To Remove Top End

    This is not the first time I've done this. The 1983 R100RS motor is built the same as the 1983 R80ST motor, so the procedure I documented for the 1983 R100RS applies here as well. Rather than duplicate that procedure, here is the link to the documentation on the 1983 R100RS which contains all the details you need to complete this work.

    This document will provide a brief summary of the procedure with pictures of what I found as I did this work on the R80ST engine and I did shoot a short video of doing this work on the R80ST.



    VIDEO: 1983 R80ST Remove Engine Top End and Cam Followers

    And here is the longer video I made for the 1983 R100RS which contains additional information you may find helpful. However, I didn't show removing the cam followers in this one.

    VIDEO: 1983 R100RS Remove Engine Top End

    Here is what the bike looks like now.

    Engine Top End Removed
    Engine Top End Removed

    Engine Top End Removed
    Engine Top End Removed

    Engine Top End Removed
    Engine Top End Removed
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

Similar Threads

  1. 1983 R100RS Rebuild Project Journal
    By brook.reams in forum Airheads
    Replies: 199
    Last Post: 05-13-2021, 04:39 PM
  2. 1973 R75/5 Rebuild Project Journal
    By brook.reams in forum Airheads
    Replies: 135
    Last Post: 07-25-2014, 05:28 PM
  3. valve cover leak 1983 R80ST
    By 92681 in forum Airheads
    Replies: 3
    Last Post: 01-06-2013, 05:18 PM
  4. 1983 R80ST Choke Trouble
    By PhantomII in forum Airheads
    Replies: 14
    Last Post: 12-25-2009, 06:15 PM

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •