1983 R80ST Rebuild For Charity Project Journal

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.

<a title="Forks Removed And Labeled" href="https://www.flickr.com/photos/brook-reams/51820363971/in/album-72177720295944273/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51820363971_485cb0557f_c.jpg" alt="Front Fork Sliders Painted Blue By Previous Owner" width="800" height="600" /></a>
Front Fork Sliders Painted Blue By Previous Owner

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

<a title="Vapor Blasted Fork Sliders" href="https://www.flickr.com/photos/brook-reams/51994283802/in/album-72177720295944273/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51994283802_b128119b2f_c.jpg" alt="Vapor Blasted Fork Sliders" width="800" height="600" /></a>
Vapor Blasted Fork Sliders

<a title="Vapor Blasted Fork Sliders" href="https://www.flickr.com/photos/brook-reams/51994283757/in/album-72177720295944273/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51994283757_951638701f_c.jpg" alt="Vapor Blasted Fork Sliders" width="800" height="600" /></a>
Vapor Blasted Fork Sliders

I use a fork rebuild kit from Tom Cutter at <a href="http://www.rubberchickenracinggarage.comn" target="_blank" rel="noopener">Rubber Chicken Racing Garage</a> and obtain the rest of the parts from <a href="http://www.euromotoelectrics.com" target="_blank" rel="noopener">Euro MotoElectrics</a> who is donating parts in support of my goal to auction this bike with all proceeds going to support the <a href="http://www.motorelief.org" target="_blank" rel="noopener">Motorcycle Relief Project</a>. 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.

<a title="Fork Sliders-All Done" href="https://www.flickr.com/photos/brook-reams/52494853841/in/album-72177720295944273/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52494853841_63ef158894_c.jpg" alt="Rebuilt, Vapor Blasted Fork Sliders With New Reflectors" width="800" height="600" /></a>
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.
<ul class="children">
<li class="page_item page-item-10566"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/31-bmw-1983-r80st-rebuild-front-forks/">31 BMW 1983 R80ST Rebuild Front Forks</a></li>
</ul>

<em><strong>VIDEO: <span style="text-decoration: underline;">1983 BMW R80ST Rebuild Front Forks</span></strong></em>

 

1983 R80ST Replace Steering Head Bearings

Folks,

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

• 31 BMW 1983 R80ST Replace Steering Head Bearings

VIDEO: 1983 R80ST Replace Steering Head Bearings

I hope this is helpful.

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.
<ul class="children">
<li class="page_item page-item-10566"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/31-bmw-1983-r80st-rebuild-front-forks/">31 BMW 1983 R80ST Rebuild Front Forks</a></li>
<li class="page_item page-item-10592"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/31-bmw-1983-r80st-replace-steering-head-bearings/">31 BMW 1983 R80ST Replace Steering Head Bearings</a></li>
</ul>
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 <a href="https://toastertan.com/" target="_blank" rel="noopener">Toaster Tan Top Brace</a> 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.

<a title="Toaster Tan R80ST Top Brace" href="https://www.flickr.com/photos/brook-reams/52525146797/in/album-72177720295944273/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52525146797_7450d862b9_c.jpg" alt="Toaster Tan R80ST Top Brace" width="800" height="600" /></a>
Toaster Tan R80ST Top Brace

You can read about how I do this work and see a summary YouTube video.
<ul class="children">
<li class="page_item page-item-10628"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/31-bmw-1983-r80st-install-align-front-forks-toaster-tan-top-brace/" target="_blank" rel="noopener">31 BMW 1983 R80ST Install-Align Front Forks & Toaster Tan Top Brace</a></li>
</ul>

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R80ST Install-Align Front Forks & Toaster Tan Top Brace</span></em></strong>

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.
<ul class="children">
<li class="page_item page-item-9628"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/61-bmw-1983-r80st-remove-electrical-system/">61 BMW 1983 R80ST Remove Electrical System</a></li>
</ul>
Here is a link to the documentation and YouTube video summary of how I do this work.
<ul class="children">
<li class="page_item page-item-10664"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/61-bmw-1983-r80st-install-electrical-system/">61 BMW 1983 R80ST Install Electrical System</a></li>
</ul>
<strong>VIDEO: <em>1983 BMW R80ST Install Electrical System</em></strong>

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.
<ul class="children">
<li class="page_item page-item-10698"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/32-bmw-1983-r80st-install-handlebars-instruments-dash/">32 BMW 1983 R80ST Install Handlebars, Instruments, Dash</a></li>
</ul>
<strong>VIDEO: <em>1983 BMW R80ST Install Handlebar, Instruments & Dash</em></strong>

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.

<a title="Front Brembo Disk Brake Caliper-Missing Rotor" href="https://www.flickr.com/photos/brook-reams/51734612799/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51734612799_5cd4f6a1c0_c.jpg" alt="As Found: Front Brembo Disk Brake Caliper And Missing Brake Rotor" width="800" height="600" /></a>
As Found: Front Brembo Disk Brake Caliper And Missing Brake Rotor

<a title="Brembo Front Brake Caliper Looking Crusty" href="https://www.flickr.com/photos/brook-reams/51813231498/in/album-72177720295872123/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51813231498_187c16c930_c.jpg" alt="Brembo Front Brake Caliper With Crusty Looking Brake Pads" width="800" height="600" /></a>
Brembo Front Brake Caliper With Crusty Looking Brake Pads

And this is how it looks after repainting and rebuilding.

<a title="Brembo Front Caliper After Rebuilding" href="https://www.flickr.com/photos/brook-reams/52591802061/in/album-72177720295872123/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52591802061_d617d291cd_c.jpg" alt="Brembo Front Caliper After Rebuilding" width="800" height="600" /></a>
Brembo Front Caliper After Rebuilding

<a title="Brembo Front Caliper After Rebuilding" href="https://www.flickr.com/photos/brook-reams/52592065474/in/album-72177720295872123/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52592065474_954d657553_c.jpg" alt="Brembo Front Caliper After Rebuilding" width="800" height="600" /></a>
Brembo Front Caliper After Rebuilding

<a title="Brembo Front Caliper After Rebuilding" href="https://www.flickr.com/photos/brook-reams/52592226835/in/album-72177720295872123/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52592226835_7e245d1933_c.jpg" alt="Brembo Front Caliper After Rebuilding" width="800" height="600" /></a>
Brembo Front Caliper After Rebuilding

This shows how I do the work.
<ul class="children">
<li class="page_item page-item-10728 current_page_item"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/34-bmw-1983-r80st-rebuild-front-brake-caliper/" aria-current="page">34 BMW 1983 R80ST Rebuild Front Brake Caliper</a></li>
</ul>
Here is a short video summarizing the procedure. It is a mix of video from the 1983 R100RS and 1983 R80ST.


<strong>VIDEO: <em>1983 BMW R80ST Rebuild Front Brake Caliper</em></strong>

 

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.
<ul class="children">
<li class="page_item page-item-10728 current_page_item"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/34-bmw-1983-r80st-rebuild-front-brake-caliper/">34 BMW 1983 R80ST Rebuild Front Brake Caliper</a></li>
</ul>
Here is the description of how install the front brake and a summary YouTube video of how I do this work.
<ul class="children">
<li class="page_item page-item-10738"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/34-bmw-1983-r80st-install-front-brakes/">34 BMW 1983 R80ST Install Front Brake</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Install Front Brake</em></strong>

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 <a href="https://www.instagram.com/coloradovaporblasting/?hl=en" target="_blank" rel="noopener">Colorado Vapor Blasting</a> 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 <a href="http://www.motorelief.org" target="_blank" rel="noopener">Motorcycle Relief Project</a>.

Here is the link to the documentation for the transmission disassembly, rebuild and assembly including pictures of the 1983 R80ST transmission.
<ul class="children">
<li class="page_item page-item-10467"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/23-bmw-1983-r80st-disassemble-rebuild-assemble-transmission/">23 BMW 1983 R80ST Disassemble, Rebuild, Assemble Transmission</a></li>
</ul>
Here are pictures of the rebuilt transmission.

<a title="Transmission Serial Number" href="https://www.flickr.com/photos/brook-reams/52639397713/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52639397713_e4c65b785c_c.jpg" alt="Transmission Serial Number-Z078854" width="800" height="600" /></a>
Transmission Serial Number-Z078854

<a title="Transmission Assembled" href="https://www.flickr.com/photos/brook-reams/52639177279/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52639177279_bb4b435fa1_c.jpg" alt="Transmission Assembled-Red Tape On Fill Plug Means I Haven't Put Gear Lube In The Transmission Yet" width="800" height="600" /></a>
Transmission Assembled-Red Tape On Fill Plug Means I Haven't Put Gear Lube In The Transmission Yet

<a title="Transmission Assembled" href="https://www.flickr.com/photos/brook-reams/52638921186/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52638921186_633651ac56_c.jpg" alt="Transmission Assembled-Rear" width="800" height="600" /></a>
Transmission Assembled-Rear

<a title="Transmission Assembled" href="https://www.flickr.com/photos/brook-reams/52639397588/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52639397588_912737c03c_c.jpg" alt="Transmission Assembled-Bottom" width="800" height="600" /></a>
Transmission Assembled-Bottom

<a title="Transmission Assembled" href="https://www.flickr.com/photos/brook-reams/52639355650/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52639355650_8e48a79e10_c.jpg" alt="Transmission Assembled-Front" width="800" height="600" /></a>
Transmission Assembled-Front

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.
<ul class="children">
<li class="page_item page-item-9773"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/23-bmw-r80st-remove-transmission/">23 BMW 1983 R80ST Remove Transmission</a></li>
<li class="page_item page-item-10467"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/23-bmw-1983-r80st-disassemble-rebuild-assemble-transmission/">23 BMW 1983 R80ST Disassemble, Rebuild, Assemble Transmission</a></li>
</ul>
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.
<ul class="children">
<li class="page_item page-item-10797"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/23-bmw-1983-r80st-install-transmission/">23 BMW 1983 R80ST Install Transmission</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Install Transmission</em></strong>

Here are the before and after pictures of the transmission.

<a title="Missing Carburetors" href="https://www.flickr.com/photos/brook-reams/51729021807/in/album-72157720265271480/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51729021807_d0518ed8a0_c.jpg" alt="Transmission Condition As I Found It" width="800" height="600" /></a>
Transmission Condition As I Found It

<a title="Transmission Shift Linkage" href="https://www.flickr.com/photos/brook-reams/51730717930/in/album-72157720265271480/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51730717930_c30597d436_c.jpg" alt="Transmission Condition As I Found It" width="800" height="600" /></a>
Transmission Condition As I Found It

<a title="Transmission Installed" href="https://www.flickr.com/photos/brook-reams/52651335156/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52651335156_bf485c9dd5_c.jpg" alt="Transmission Installed" width="800" height="600" /></a>
Transmission Installed

<a title="Transmission Installed" href="https://www.flickr.com/photos/brook-reams/52651816763/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52651816763_e46ea24857_c.jpg" alt="Transmission Installed" width="800" height="600" /></a>
Transmission Installed

1983 R80ST Rebuild Rear Drive

I suspect the final drive seals are leaking, and this bike has been sitting for about 25 years. So I am rebuilding and refinishing the rear drive. I have never rebuilt a rear drive before and I understand this requires some special tools and also correct shimming of the pinion and crown gear; aka, ring gear. So I asked Matt Iles, owner of <a href="https://ilesmotorsports.com/" target="_blank" rel="noopener">Iles Motorsports,</a> if I could watch him do this work, and he agreed. I have Matt replace all the seals and bearings in the final drive so it will be good for another 40 years and 100,000 miles. That way I get an education about how this is done so I can decide if I am capable of doing this work in the future. Any mistakes in this documentation are on me, not Matt.

Here is the link to my documentation of Matt's work.
<ul class="children">
<li class="page_item page-item-10538"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/33-bmw-1983-r80st-rebuild-final-drive/">33 BMW 1983 R80ST Rebuild Final Drive</a></li>
</ul>Here are some before and after pictures.

<a title="Draining Swing Arm Gear Lube" href="https://www.flickr.com/photos/brook-reams/51831287524/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51831287524_233b48ff1d_c.jpg" alt="Original Rear Drive Before Removal From Swing Arm" width="800" height="600" /></a>
Original Rear Drive Before Removal From Swing Arm

<a title="Rear Drive Removed" href="https://www.flickr.com/photos/brook-reams/52470554952/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52470554952_2cb8624dfb_c.jpg" alt="Rear Drive Case Before Vapor Blasting" width="800" height="600" /></a>
Rear Drive Case Before Vapor Blasting

<a title="Rebuilt Rear Drive" href="https://www.flickr.com/photos/brook-reams/52645043346/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52645043346_b4ea0eb8e4_c.jpg" alt="Vapor Blasted, Rebuilt Rear Drive" width="800" height="600" /></a>
Vapor Blasted, Rebuilt Rear Drive

<a title="Rebuilt Rear Drive" href="https://www.flickr.com/photos/brook-reams/52645516313/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52645516313_462a9b5507_c.jpg" alt="Vapor Blasted, Rebuilt Rear Drive" width="800" height="600" /></a>
Vapor Blasted, Rebuilt Rear Drive

<a title="Rebuilt Rear Drive" href="https://www.flickr.com/photos/brook-reams/52645298499/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52645298499_6688d3668b_c.jpg" alt="Vapor Blasted, Rebuilt Rear Drive" width="800" height="600" /></a>
Vapor Blasted, Rebuilt Rear Drive

1983 R80ST Install Swing Arm, Rear Drive, Monoshock

I had the rear drive rebuilt by a friend of mine, Matt Iles, who owns <a href="https://ilesmotorsports.com/" target="_blank" rel="noopener">Iles Motorsports</a> and is a long time BMW mechanic. You can read about how he did this work here.
<ul class="children">
<li class="page_item page-item-10538"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/33-bmw-1983-r80st-rebuild-final-drive/">33 BMW 1983 R80ST Rebuild Rear Drive</a></li>
</ul>
I replaced the swing arm bearings and you can read about how I do that here.
<ul class="children">
<li class="page_item page-item-10276"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/33-bmw-1983-r80st-replace-swing-arm-bearings/">33 BMW 1983 R80ST Replace Swing Arm Bearings</a></li>
</ul>
The R80ST has a monoshock rear suspension instead of the traditional dual shock suspension that was on all the other airhead bikes I have worked on. So the swing arm is a bit different. The procedure for installing the swing arm and rear drive on the 1983 R80ST is the same as for the 1983 R100RS.

Here is the link to the documentation and a summary YouTube video.
<ul class="children">
<li class="page_item page-item-10821"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/33-bmw-1983-r80st-install-swing-arm-rear-drive-monoshock/">33 BMW 1983 R80ST Install Swing Arm, Rear Drive, Monoshock</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Install Swing Arm, Rear Drive, Monoshock</em></strong>

Here are some before and after pictures.

<a title="Rear Shock" href="https://www.flickr.com/photos/brook-reams/51733142462/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51733142462_ee7c5dff84_c.jpg" alt="Original Rear Shock" width="800" height="600" /></a>
Original Rear Shock

<a title="Rear Drive" href="https://www.flickr.com/photos/brook-reams/51734612204/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51734612204_8eb68ca247_c.jpg" alt="Original Rear Drive" width="800" height="600" /></a>
Original Rear Drive

<a title="Rear Drive, Swing Arm & Rear Monoshock" href="https://www.flickr.com/photos/brook-reams/51829992367/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51829992367_7358df005e_c.jpg" alt="Original Swing Arm, Rear Drive & Monoshock" width="800" height="600" /></a>
Original Swing Arm, Rear Drive & Monoshock

Here is the R80ST with the swing arm, rear drive and monoshock installed. It's starting to look like a real motorcycle again.

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52661671741/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52661671741_4e5e826dc1_c.jpg" alt="All Done" width="800" height="600" /></a>
All Done

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52661171407/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52661171407_d68a1b6a4a_c.jpg" alt="All Done" width="800" height="600" /></a>
All Done

1983 R80ST Install Rear Brake

The rear brake on the 1983 R80ST is a drum brake.

Here is a link to the documentation and a short YouTube video summary of how I do this work.
<ul class="children">
<li class="page_item page-item-10854"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/34-bmw-1983-r80st-install-rear-brake/">34 BMW 1983 R80ST Install Rear Brake</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Install Rear Brake</em></strong>

Here is the final product.

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52672568267/in/album-72177720295872123/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52672568267_6c47fd91d4_c.jpg" alt="All Done" width="800" height="600" /></a>
All Done

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52673355279/in/album-72177720295872123/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52673355279_47aa209b23_c.jpg" alt="All Done" width="800" height="600" /></a>
All Done

1983 R80ST Install Crash Bars, Side And Center Stand

The left side crash bar on the R80ST includes a bracket for the side stand. So I start by installing the crash bars, then the side stand. Then I put the bike on the side stand and install the center stand.

Here is how I removed all those parts.
<ul class="children">
<li class="page_item page-item-9682"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/46-bmw-1983-r80st-remove-center-stand-crash-bars-and-side-stand/">46 BMW 1983 R80ST Remove Center Stand, Crash Bars and Side Stand</a></li>
</ul>
Here is the documentation and short summary video showing the installation.
<ul class="children">
<li class="page_item page-item-10918"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/46-bmw-1983-r80st-install-crash-bars-side-and-center-stand/">46 BMW 1983 R80ST Install Crash Bars, Side And Center Stand</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Install Crash Bars, Side And Center Stands</em></strong>

1983 R80ST Install Exhaust System

This R80ST came with no right exhaust header or collector box. I decided to replace the entire exhaust system as the rear muffler and left header had a fair amount of rust.

<a title="Wrong Orientation Of Left Side Exhaust Pipe" href="https://www.flickr.com/photos/brook-reams/52782740414/in/album-72177720307131275/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52782740414_d9d9522c87_c.jpg" alt="Left Header Pipe Mounted Wrong And Rear Muffler" width="800" height="600" /></a>
Left Header Pipe Mounted Wrong And Rear Muffler

<a title="Corrosion On Muffler" href="https://www.flickr.com/photos/brook-reams/51730082263/in/album-72157720265271480/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51730082263_ecb3786f2a_c.jpg" alt="Corrosion On Muffler" width="800" height="600" /></a>
Corrosion On Muffler

<a title="Right Side Missing Exhaust Header & Crash Bar" href="https://www.flickr.com/photos/brook-reams/51729833911/in/album-72157720265271480/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51729833911_b7113535fb_c.jpg" alt="Right Side Missing Exhaust Header" width="800" height="600" /></a>
Right Side Missing Exhaust Header

Here is the new exhaust system installed. I'll install the muffler heat shield when I get the side panel back from the painter.

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52816603132/in/dateposted-public/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52816603132_9b7dc28dbe_c.jpg" alt="All Done" width="800" height="600" /></a>
All Done

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52817572495/in/dateposted-public/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52817572495_e462181147_c.jpg" alt="All Done" width="800" height="600" /></a>
All Done

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52816603082/in/dateposted-public/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52816603082_1e0f40e140_c.jpg" alt="All Done" width="800" height="600" /></a>
All Done

This is a link to the documentation and a short YouTube video summary of how I do this work.
<ul class="children">
<li class="page_item page-item-10952 current_page_item"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/18-bmw-1983-r80st-install-exhaust-system/" aria-current="page">18 BMW 1983 R80ST Install Exhaust System</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Install Exhaust System</em></strong>

1983 R80ST Install Fenders

The 1983 R80ST "project bike" came with a rear fender but no front fender. A friend of mine donated a front fender for this charity rebuild project. It took awhile to get the parts back from the painter. Unlike the fenders on many other airhead models, the R80ST fenders do not have pinstripes. Here are pictures of what I started with and what the newly painted parts look like.

<a title="Donated Front Fender" href="https://www.flickr.com/photos/brook-reams/52998314221/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52998314221_116a5d4391_c.jpg" alt="Donated Front Fender" width="800" height="600" /></a>
Donated Front Fender

<a title="Donated Front Fender" href="https://www.flickr.com/photos/brook-reams/52998314241/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52998314241_b1ec11c6d2_c.jpg" alt="Donated Front Fender" width="800" height="600" /></a>
Donated Front Fender

<a title="R80ST Painted Front Fender" href="https://www.flickr.com/photos/brook-reams/52979268476/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52979268476_f1e34a3fa9_c.jpg" alt="R80ST Painted Front Fender" width="800" height="600" /></a>
R80ST Painted Front Fender

<a title="Rear Fender Detail" href="https://www.flickr.com/photos/brook-reams/51743484999/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51743484999_2b837dae88_c.jpg" alt="Original Rear Fender" width="800" height="600" /></a>
Original Rear Fender

<a title="Rear Fender Detail" href="https://www.flickr.com/photos/brook-reams/51742018637/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51742018637_879a0343fc_c.jpg" alt="Original Rear Fender" width="800" height="600" /></a>
Original Rear Fender

<a title="R80ST Painted Rear Fender" href="https://www.flickr.com/photos/brook-reams/52979724693/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52979724693_4c2d70d6d4_c.jpg" alt="R80ST Painted Rear Fender" width="800" height="600" /></a>
R80ST Painted Rear Fender

Here is a link to the documentation of how I did the work, and a summary video.
<ul class="wp-block-navigation__submenu-container">
<li class="wp-block-pages-list__item "><a class="wp-block-pages-list__item__link" href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/46-bmw-1983-r80st-install-fenders/">46 BMW 1983 R80ST Install Fenders</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Install Fenders</em></strong>

1983 R80ST Assemble & Install Gas Tank

This "project bike" came with it's original gas tank. There was a small dent in the tank near the front and scrapes and gashes in the paint. The inside red tank lining was in good condition. I had it repaired and repainted. I refurbished the gas cap, put on new BMW roundels, replaced the rear bracket that secures the tank to the spine tube and installed new fuel lines.

Here are some before and after pictures of the gas tank.

<a title="Gas Tank Pinstripe Detail" href="https://www.flickr.com/photos/brook-reams/51742018597/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51742018597_47682614c2_c.jpg" alt="Original Gas Tank Condition" width="800" height="600" /></a>
Original Gas Tank Condition

<a title="Gas Tank Detail" href="https://www.flickr.com/photos/brook-reams/51743484864/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51743484864_60aae62e18_c.jpg" alt="Original Gas Tank Condition" width="800" height="600" /></a>
Original Gas Tank Condition

<a title="Gas Tank Detail" href="https://www.flickr.com/photos/brook-reams/51742843216/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51742843216_21ed0f4f6c_c.jpg" alt="Original Gas Tank Condition" width="800" height="600" /></a>
Original Gas Tank Condition

<a title="Gas Tank Detail" href="https://www.flickr.com/photos/brook-reams/51743079883/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51743079883_7c90e80647_c.jpg" alt="Dent In Front Of Original Gas Tank" width="800" height="600" /></a>
Dent In Front Of Original Gas Tank

<a title="R80ST Painted Gas Tank" href="https://www.flickr.com/photos/brook-reams/52979642690/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52979642690_4a6f1fbf84_c.jpg" alt="R80ST Painted Gas Tank" width="800" height="600" /></a>
R80ST Painted Gas Tank

<a title="R80ST Painted Gas Tank" href="https://www.flickr.com/photos/brook-reams/52979642715/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52979642715_08b3d72777_c.jpg" alt="R80ST Painted Gas Tank" width="800" height="600" /></a>
R80ST Painted Gas Tank

<a title="R80ST Inside Gas Tank" href="https://www.flickr.com/photos/brook-reams/52978669682/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52978669682_107e9937e9_c.jpg" alt="R80ST Inside Gas Tank" width="800" height="600" /></a>
R80ST Inside Gas Tank

Here it is installed on the bike.

<a title="Gas Tank Installed" href="https://www.flickr.com/photos/brook-reams/52997761947/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52997761947_2389d7f591_c.jpg" alt="Gas Tank Installed" width="800" height="600" /></a>
Gas Tank Installed

<a title="Gas Tank Installed" href="https://www.flickr.com/photos/brook-reams/52998358556/in/album-72177720309303749/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52998358556_48a6169113_c.jpg" alt="Gas Tank Installed" width="800" height="600" /></a>
Gas Tank Installed

This is a link to the documentation of how I did this work and a summary video of the procedure.

• 16 BMW 1983 R80ST Assemble & Install Gas Tank

<strong><span style="color: #000000;">VIDEO: <em>1983 BMW R80ST Assemble & Install Gas Tank</em></span></strong>

1983 R80ST First Engine Start

I completed the first engine start and a 10 mile break-in ride. You can see the details here.
<ul class="wp-block-navigation__submenu-container">
<li class="wp-block-pages-list__item "><a class="wp-block-pages-list__item__link" href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-r80st-first-engine-start/">11 BMW R80ST First Engine Start</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST First Engine Start</em></strong>

Type 247 Podcast About This Project

Folks,

Daren Dortin posted a podcast on his Type 247 podcast site about this project today. You can listen to it on either of these links. You can hear more about the charity, Motorcycle Relief Project, that I am going to contribute the proceeds of the auction of this bike to.

https://podcasts.apple.com/us/podcast/airhead-247-podcast-brook-reams-r80st-motorcyclerelief/id1612340502i=1000618880353


https://open.spotify.com/episode/1wlHuxQ7zOPLQgRnnsI5y7

1983 R80ST Paint Pinstripes

This video shows how Joe Broxterman of Speedway Graphics applies the pinstripes. Joe was gracious and donated the pinstripes in support of my charity auction of the bike for the Motorcycle Relief Project.


VIDEO: 1983 BMW R80ST Paint Pinstripes

1983 R80ST Install Side Covers & Muffler Heat Shield

When I got this bike I found the left side cover, but not the right. <a href="http://thenickwackettgarage.com/bmwtwin/" target="_blank" rel="noopener">Bud Provin of The Nickwackett Garage</a> offered to supply me a new right side cover at no cost in support of my project goal to auction this bike and donate all the proceeds to the <a href="http://www.motorelief.org" target="_blank" rel="noopener">Motorcycle Relief Project</a>.

I wasn't able to get an ST muffler, so I installed an R80 G/S muffler from <a href="http://www.keihan.co.uk/" target="_blank" rel="noopener">Keihan Systems</a> in the UK. They provide an adapter kit to mount the ST heat shield on the G/S muffler.

I also had to repair the original left side cover tabs as several were broken.

Here is the link to the documentation and the summary video of how I did this work.
<ul class="wp-block-navigation__submenu-container">
<li class="wp-block-pages-list__item "><a class="wp-block-pages-list__item__link" href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/46-bmw-r80st-install-side-covers-muffler-heat-shield/">46 BMW R80ST Install Side Covers & Muffler Heat Shield</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Install Side Covers & Muffler Heat Shield</em></strong>