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Thread: 1983 R80ST Rebuild For Charity Project Journal

  1. #61
    B Reams brook.reams's Avatar
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    1983 R80ST Rebuild Front Forks

    The 1983 R80ST "project bike" came with both front fork legs, although a previous owner had painted the fork sliders blue. One leg is missing the yellow reflector and the black fork seal cover.

    Front Fork Sliders Painted Blue By Previous Owner
    Front Fork Sliders Painted Blue By Previous Owner

    I had the fork sliders vapor blasted to freshen up the forks and remove the paint.

    Vapor Blasted Fork Sliders
    Vapor Blasted Fork Sliders

    Vapor Blasted Fork Sliders
    Vapor Blasted Fork Sliders

    I use a fork rebuild kit from Tom Cutter at Rubber Chicken Racing Garage and obtain the rest of the parts from Euro MotoElectrics who is donating parts in support of my goal to auction this bike with all proceeds going to support the Motorcycle Relief Project. I will install some of the parts in Tom's fork rebuild kit and the new fork springs when I install the forks in the top plate and triple clamp.

    In addition to rebuilding the forks, I replace the large Allen bolt that secures the fork slider to the damper rod (part# 07 11 9 919 778) as they got mangled a bit when I removed them. I replace the fork top cap bolts (part# 31 42 1 241 661) as they are in bad shape. I also replace the yellow side reflectors (part# 63 14 1 244 529) as one was missing and the other was cracked.

    Rebuilt, Vapor Blasted Fork Sliders With New Reflectors
    Rebuilt, Vapor Blasted Fork Sliders With New Reflectors[/caption]


    Here is a link to the document showing how I do this work and a YouTube summary video of the procedure.



    VIDEO: 1983 BMW R80ST Rebuild Front Forks

     
    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. #62
    B Reams brook.reams's Avatar
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    1983 R80ST Replace Steering Head Bearings

    Folks,

    I completed this work and published a document and YouTube video showing how I do this work.





    VIDEO: 1983 R80ST Replace Steering Head Bearings

    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

  3. #63
    B Reams brook.reams's Avatar
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    1983 R80ST Install-Align Front Forks & Toaster Tan Top Brace

    This 1983 R80ST "project bike" had the front forks and the BMW top plate when I acquired it. I rebuilt the front forks and replaced the steering head bearings and you can read about how I do that work here.

    Now it's time to install and align the front forks. I replace the stock BMW top plate that fits over the steering stem and on top of the fork tubes with a Toaster Tan Top Brace and the Toaster Tan acorn nut that secures the top brace to the steering stem. This top plate is much stronger than the stock thin steel top plate BMW uses. This improves handling as the top plate doesn't bend and flex like the BMW top plate does.

    Toaster Tan R80ST Top Brace
    Toaster Tan R80ST Top Brace

    You can read about how I do this work and see a summary YouTube video.



    VIDEO: 1983 BMW R80ST Install-Align Front Forks & Toaster Tan Top Brace
    Last edited by brook.reams; 12-05-2022 at 06:49 PM.
    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

  4. #64
    B Reams brook.reams's Avatar
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    1983 R80ST Install Electrical System

    I replace the main wiring harness and all the sub-harnesses. I also replace all the electrical components. Since this bike sat for almost 25 years and the components and wiring were not in good shape, replacing it all should provide very good reliability. You can see how I remove what was left of the original electrical system here.

    Here is a link to the documentation and YouTube video summary of how I do this work.


    VIDEO: 1983 BMW R80ST Install Electrical System
    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

  5. #65
    B Reams brook.reams's Avatar
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    1983 R80ST Install Handlebars, Instruments And Dash

    After I installed the electrical system, I install the handlebars, the instruments (speedometer and tachometer), the dash and the handlebar controls and multi-function switches. You can see how I did this work and a summary YouTube video below.


    VIDEO: 1983 BMW R80ST Install Handlebar, Instruments & Dash
    Last edited by brook.reams; 01-04-2023 at 01:23 AM.
    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. #66
    B Reams brook.reams's Avatar
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    1983 R80ST Rebuild Front Brake Caliper

    The 1983 R80ST has a single front disk brake on the right side of the front wheel. It uses a Brembo caliper connected to a master cylinder and fluid reservoir built into the right handlebar control unit. I repainted the caliper using black caliper paint.

    Here is what the caliper looked like when I got the bike removed it from the bike.

    As Found: Front Brembo Disk Brake Caliper And Missing Brake Rotor
    As Found: Front Brembo Disk Brake Caliper And Missing Brake Rotor

    Brembo Front Brake Caliper With Crusty Looking Brake Pads
    Brembo Front Brake Caliper With Crusty Looking Brake Pads

    And this is how it looks after repainting and rebuilding.

    Brembo Front Caliper After Rebuilding
    Brembo Front Caliper After Rebuilding

    Brembo Front Caliper After Rebuilding
    Brembo Front Caliper After Rebuilding

    Brembo Front Caliper After Rebuilding
    Brembo Front Caliper After Rebuilding

    This shows how I do the work.

    Here is a short video summarizing the procedure. It is a mix of video from the 1983 R100RS and 1983 R80ST.



    VIDEO: 1983 BMW R80ST Rebuild Front Brake Caliper

     
    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. #67
    B Reams brook.reams's Avatar
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    1983 R80ST Install Front Brake

    The 1983 R80ST has a single front disk brake. The brake disk is mounted on the right side of the front wheel. This bike did not have the front disk, so I got a new one. I rebuilt the front brake caliper and you can see how I do that here.

    Here is the description of how install the front brake and a summary YouTube video of how I do this work.



    VIDEO: 1983 BMW R80ST Install Front Brake
    Last edited by brook.reams; 12-31-2022 at 12:40 AM.
    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. #68
    B Reams brook.reams's Avatar
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    1983 R80ST Disassemble, Rebuild, Assemble Transmission

    The 1983 R80ST transmission is the same as the 1983 R100RS transmission that I rebuilt previously. So in this document, I provide links to the 1983 R100RS documents showing how I disassemble, rebuild and reassemble the transmission. I will provide pictures and details about what I find when I open up the R80ST transmission and will document any work I have to do on the R80ST that is different from the work I did on the R100RS.

    I have the transmission cases vapor blasted by Colorado Vapor Blasting in Arvada, CO who is generously providing a discount to me in support of my goal of a charity auction of this R80ST to support the Motorcycle Relief Project.

    Here is the link to the documentation for the transmission disassembly, rebuild and assembly including pictures of the 1983 R80ST transmission.

    Here are pictures of the rebuilt transmission.

    Transmission Serial Number-Z078854
    Transmission Serial Number-Z078854

    Transmission Assembled-Red Tape On Fill Plug Means I Haven't Put Gear Lube In The Transmission Yet
    Transmission Assembled-Red Tape On Fill Plug Means I Haven't Put Gear Lube In The Transmission Yet

    Transmission Assembled-Rear
    Transmission Assembled-Rear

    Transmission Assembled-Bottom
    Transmission Assembled-Bottom

    Transmission Assembled-Front
    Transmission Assembled-Front
    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

  9. #69
    B Reams brook.reams's Avatar
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    1983 R80ST Install Transmission

    After removing the transmission, I disassembled it, had the case and rear cover vapor blasted, rebuilt the shift cam assembly, input, intermediate and output shafts and reassembled the transmission. You can read about that work here.

    So, now I'm ready to install it. I also install the clutch throw-out lever assembly, foot shifter assembly, clutch cable and speedometer cable. Here is a link to the documentation about installing the 1983 R80ST transmission and a YouTube video.



    VIDEO: 1983 BMW R80ST Install Transmission

    Here are the before and after pictures of the transmission.

    Transmission Condition As I Found It
    Transmission Condition As I Found It

    Transmission Condition As I Found It
    Transmission Condition As I Found It

    Transmission Installed
    Transmission Installed

    Transmission Installed
    Transmission Installed
    Last edited by brook.reams; Yesterday at 04:19 PM.
    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

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