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Thread: 1983 R80ST Rebuild For Charity Project Journal

  1. #31
    B Reams brook.reams's Avatar
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    1983 R80ST Remove And Test Starter Motor

    Since this project bike was not running when I picked it up and had been sitting outside for awhile, I don't know what components of the electrical system work. So I remove the starter motor and test it.

    What The 1983 R80ST Looked Like When I Found It
    What The 1983 R80ST Looked Like When I Found It

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




    VIDEO: 1983 BMW R80ST Remove And Test Starter Motor

    The good news is the starter motor was in good condition and worked correctly. :-) I cleaned up the starter motor and the top engine compartment it sits in.

    Starter Motor Nose Refinished
    Starter Motor Nose Refinished

    Front Starter Motor Bracket Refinished
    Front Starter Motor Bracket Refinished

    Top Engine Housing Is Clean
    Top Engine Housing Is Clean
    Last edited by brook.reams; 03-30-2022 at 01:37 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

  2. #32
    B Reams brook.reams's Avatar
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    1983 R80ST Remove, Inspect, Install Oil Pump

    I've removed the airbox, transmission, clutch and flywheel to gain access to the oil pump. You can see how I did that work here.

    I've published documents on removing, inspecting and installing the oil pump on other projects. Here are links to those documents.

    Here is the link to how I do the work on the 1983 R80ST.

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



    VIDEO: 1983 BMW R80ST Remove And Inspect Oil Pump

    Oil Pump Cover Removed
    Oil Pump Cover Removed

    Oil Pump Rotors Marked With "F" For Front Face
    Oil Pump Rotors Marked With "F" For Front Face

    Oil Pump Measurements - They Are All Good
    Oil Pump Measurements - They Are All Good
    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. #33
    B Reams brook.reams's Avatar
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    1983 R80ST Replace Rear Main Seal

    I've removed the airbox, transmission, clutch and flywheel to gain access to the rear main seal so I can replace it. You can see how I did that work here.

    I've published documents on replacing the rear main seal on other projects. Here are links to those documents.

    Since the 1983 R80ST engine is similar in many ways to the 1983 R100RS, I link to the 1983 R100RS documents as appropriate in this document.

    Here is a short YouTube video showing how I do this work.



    VIDEO: 1983 BMW R80ST Replace Rear Main Seal

    I had a real problem removing the seal on this bike using my usual approach with the Cycle Works rear main seal tool, and had to resort to using "a bigger hammer". I used a hook seal puller to pry the old rear main seal out of the bore. Since the bike has been sitting for 25-30 years, the seal was really stuck in the bore.

    Cycle Works Rear Main Seal Tool
    Cycle Works Rear Main Seal Tool

    Using Hook Seal Puller To Remove Rear Main Seal
    Using Hook Seal Puller To Remove Rear Main Seal

    Using Flashlight To Verify Seal Is Flush With Case
    Using Flashlight To Verify Seal Is Flush With Case
    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. #34
    B Reams brook.reams's Avatar
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    1983 R80ST Install Flywheel

    I've removed the airbox, transmission and clutch to gain access to the flywheel. You can see how I did that work here.

    I also show how to remove the flywheel here.

    I've published documents on removing and installing the flywheel on other projects. You can see those documents here.

    Since the 1983 R80ST engine is similar in many ways to the 1983 R100RS, I will link to the 1983 R100RS documents as appropriate in this document.

    Here is a short YouTube video showing how I do this work.



    VIDEO: 1983 BMW R80ST Install Flywheel

    Here is how things look now.

    Flywheel Installed
    Flywheel Installed
    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. #35
    Very impressive sir, thanks for all the sharing and knowledge you bring to the group
    The lion does not even bother to turn his head when he hears the small dog barking.

    https://www.youtube.com/user/azqkr

  6. #36
    B Reams brook.reams's Avatar
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    Quote Originally Posted by brownie0486 View Post
    Very impressive sir, thanks for all the sharing and knowledge you bring to the group
    You're welcome brownie0486.
    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. #37
    B Reams brook.reams's Avatar
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    1983 R80ST Install Clutch

    Well, all the work on the rear of the engine is finished as I have completed installing a new clutch provided for free from Euro MotoElectrics who offered to provide free parts for this charity rebuild project to benefit the Motorcycle Relief Project.

    Here is the link to the document about how I did this work.


    I also shot a short video summarizing the work.



    VIDEO: 1983 BMW R80ST Install Clutch

    Here are some before and after pictures of the clutch. This one should be good for the next 100,000 miles.

    Original R80ST Clutch
    Original R80ST Clutch Looks Very Bedraggled

    Original Clutch Condition
    Original Clutch Condition

    New EME Supplied Clutch Pack Assembled For Installation On Face Of Flywheel
    New EME Supplied Clutch Pack Assembled For Installation On Face Of Flywheel

    New Clutch Installed
    New Clutch Installed
    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. #38
    B Reams brook.reams's Avatar
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    1983 R80ST Remove Alternator, Diode Board & Electronic Ignition Sensor

    This "project" bike has been sitting for over 25 years. So, for reliability, I'm going to replace the charging system which consists of the alternator, diode board and all associated wiring. I may try to rebuild the electronic ignition sensor, aka, the "bean can" that uses a Hall effect sensor to trigger the ignition. This document covers how I remove the components.

    Also, I plan to replace the timing chain, crankshaft timing sprocket and the nose bearing which are behind the inner timing cover that the charging system and electronic ignition sensor are mounted to, so I have to remove all these components before I can remove the inner timing cover.

    The original alternator looks a bit bedraggled.

    Original Alternator Looks Bedraggled
    Original Alternator Looks Bedraggled

    I've replaced charging systems on other projects. Here are links to those documents.

    Here is what the inner timing cover looks like after all the engine electrical components are removed.

    Inner Timing Cover After Engine Electrical Components Removed
    Inner Timing Cover After Engine Electrical Components Removed

    Here is a link to the document showing how I do this work, and a short YouTube video summarizing the work.



    VIDEO: 1983 BMW R80ST Remove Alternator, Diode Board & Electronic Ignition Sensor
    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. #39
    B Reams brook.reams's Avatar
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    1983 R80ST Replace Timing Chain, Crankshaft Timing Sprocket & Nose Bearing

    This "project" bike has over 63,000 miles on it. It's not uncommon for the timing chain and crankshaft sprocket to wear enough at that mileage to affect valve timing. Too much slack causes uneven timing of the valves. If valve timing varies, then ignition timing will not be optimal. In situations with a lot of wear, the chain can be heard slapping inside the motor. As I've never heard this bike run, I do not know if the timing chain is that loose, but that much slop in the timing chain is more common at 100,000+ miles on the chain.

    I repainted the inner timing cover and you can read about that work here:

    Here is a link to the document showing how I do this work and some videos summarizing the work. Since I can only embed one video per posting, the other videos are included as links.
    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

  10. #40
    B Reams brook.reams's Avatar
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    1983 R80ST Replace Oil Pan & Oil Suction Flange Gaskets-Get Oil Pan Flat

    Since this bike sat for more than 25 years, I replaced the the oil pan and oil pump suction gaskets. The oil pump suction gasket was brittle so it was time to replace it. None of the oil pan bolt threads were stripped, so that was a good thing. I also had the oil pan, that was painted orange by a previous owner, vapor blasted by the Colorado Vapor Blasting division of Vintage Twins, a local independent shop in my hometown of Arvada, CO. When I told them I was going to auction this bike and donate all the proceeds to the Motorcycle Relief Project, they generously provided me a nice discount on the work. :-)

    Here is a before and after picture of the oil pan.

    The Original Orange Oil Pan
    The Original Orange Oil Pan

    All Done With Vapor Blasted Oil Pan
    All Done With Vapor Blasted Oil Pan

    All Done With Vapor Blasted Oil Pan
    All Done With Vapor Blasted Oil Pan

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

  11. 11 BMW 1983 R80ST Replace Oil Pan & Oil Pump Suction Flange Gaskets




  12. VIDEO: 1983 BMW R80ST Replace Oil Pan and Oil Pump Suction Flange Gasket
    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. #41
    B Reams brook.reams's Avatar
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    1983 R80ST Replace Connecting Rod Crankshaft Bearings, Measure Crankshaft Journal

    Since this bike sat for more than 25 years and I found water in the oil pan, I replaced the connecting rod bearings. The bearings were in good condition and the crankshaft journals were not rusted and were well within specifications, so that was a relief. I replaced the bearing shells anyway rather than reuse the original ones that had 64,000+ miles on them.

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


    VIDEO: 1983 BMW R80ST Replace Connecting Rod Crankshaft Bearings
    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

  14. #42
    B Reams brook.reams's Avatar
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    1983 R80ST Install Alternator, Diode Board & Electronic Ignition Sensor, aka, Beancan

    I replaced these components with new ones supplied my Euro MotoElectrics at no cost to me in support of my goal to auction this bike and donate all the proceeds to the Motorcycle Relief Project. EME has been very kind and generous to me on this project.
    I installed their new Type 1 charging system kit, the EDL-1 107, which has all the parts to replace the stock 240 watt charging system including a new front crankshaft seal.

    I also installed their remanufactured electronic ignition sensor, aka, the "Bean Can", and a new ignition system sub-harness.

    You can read about how I did the work and see a YouTube video.




    VIDEO: 1983 BMW R80ST Install Alternator, Diode Board & Electronic Ignition Sensor

    This is what I started with.

    Original Engine Electrical Components Under The Front Engine Cover
    Original Engine Electrical Components Under The Front Engine Cover

    Original Diode Board
    Original Diode Board

    Original Alternator
    Original Alternator

    Original Bean Can
    Original Bean Can

    And this is the final result.

    All Done
    All Done
    Last edited by brook.reams; 05-09-2022 at 11:28 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

  15. #43
    B Reams brook.reams's Avatar
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    1983 R80ST Cylinder Measurement & Honing

    This bike has the Nikasil plated aluminum cylinders. Nikasil is a nickel silicon carbide material that is extremely hard and wears very little and can be platted onto aluminum. That said, I want to measure the cylinders to determine if they are in good condition since the bike sat for about 25 years and had 64,000 miles on it.

    Insert Bore Gauge Into Cylinder & Align With Top Measurement Circle
    Insert Bore Gauge Into Cylinder & Align With Top Measurement Circle

    I previously measured the cylinders on my 1973 R75/5 and you can see that procedure here.

    On this bike, I measure the bore, ovality and taper using a bore gauge to see if these cylinders are still serviceable. I found Both cylinders are in good condition.

    Bore Gauge Kit
    Bore Gauge Kit

    After measuring the cylinders I remove the glaze on the cylinder walls using a ball hone. I use the Brush Research Flex-HoneŽ with 240 grit aluminum-oxide balls that they recommend for Nikasil cylinders. I use a 3-1/2 inch hone and my portable electric drill that has a low speed range of 600 RPM which is within the recommended 500-800 RPM Brush Research recommends.

    Brush Research Flex-Hone Ball Hone & Honing Oil {I Bought WAYYYYY Too Much :-) }
    Brush Research Flex-Hone Ball Hone & Honing Oil {I Bought WAYYYYY Too Much :-) }

    After Honing-Good 45 Degree Cross-Hatch
    After Honing-Good 45 Degree Cross-Hatch]

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


    VIDEO: 1983 BMW R80ST Cylinder Measurements & Honing
    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

  16. #44
    Back in the saddle again mikegalbicka's Avatar
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    Great job documenting this for others. Learning a lot as you step through this project. Keep up the good work and thanks for your efforts.

  17. #45
    B Reams brook.reams's Avatar
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    1983 R80ST Remove & Install Drive Shaft

    I had the swing arm powder coated, so I removed the drive shaft before taking it to the powder coater.

    The 1983 R80ST swing arm is designed for a monoshock rear suspension, but the driveshaft is the same as the one used in the dual shock 1983 R100RS. I previously removed and installed the driveshaft in a 1983 R100RS and documented the work.

    1983 R100RS Dual Shock Swing Arm Design
    1983 R100RS Dual Shock Swing Arm Design

    1983 R80ST Powder Coated Monoshock Swing Arm Design
    1983 R80ST Powder Coated Monoshock Swing Arm Design

    This is a link to the documentation and a YouTube video showing how I remove and install the drive shaft.



    VIDEO: 1983 BMW R80ST Remove & Install Driveshaft
    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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