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Thread: 1983 R80ST Rebuild For Charity Project Journal

  1. #46
    B Reams brook.reams's Avatar
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    1983 R80ST Replace Swing Arm Bearings

    I removed the swing arm bearings before I had the swing arm powder coated. The swing arm bearings are the same sealed bearings used on the 1983 R100RS that I previously rebuilt, so the procedure for replacing them on the R80ST is the same. In this document I link to the previous documentation for the 1983 R100RS as appropriate.


    Here is a short video summarizing the work.



    VIDEO: 1983 BMW R80ST Replace Swing Arm Bearings

    Earlier versions of the airhead swing arm used traditional bearings with a separate inner and outer race. I show how to replace that style swing arm bearing here.
    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. #47
    B Reams brook.reams's Avatar
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    1983 R80ST Replace Push Rod Tubes

    I had the cylinders vapor blasted. In preparation, I removed the push rod tubes. After they were vapor blasted I install new stainless steel pushrod tubes I got from Euro MotoElectrics, who graciously has agreed to provide the parts for this charity rebuild project for free. I will auction this bike and proceeds will go to the Motorcycle Relief Project.

    I have done this work before on my 1983 R100RS rebuild and will reference material from the documentation of that build as appropriate.

    Here is what I started with before vapor blasting the cylinders and replacing the push rod tubes.

    Original Cylinder And Push Rod Tubes
    Original Cylinder And Push Rod Tubes

    Here is a link to the documentation and a short YouTube video summarizing the procedure.


    VIDEO: 1983 BMW R80ST Replace Push Rod Tubes

    This is the final result.

    New Stainless Steel Push Rod Tubes Installed In Vapor Blasted Cylinders
    New Stainless Steel Push Rod Tubes Installed In Vapor Blasted Cylinders
    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. #48
    Registered User slowpokepete's Avatar
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    Excellent, as always, Brook.

    Do you have any idea when you might complete the restoration?

    SPP
    Member # 222067

  4. #49
    B Reams brook.reams's Avatar
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    Quote Originally Posted by slowpokepete View Post
    Excellent, as always, Brook.

    Do you have any idea when you might complete the restoration?

    SPP
    Pete,

    Indeed, I know exactly when I'll complete this restoration: The second I'm done. :-) I hope to be done in 2023, which is the 40th anniversary of the introduction of the R80ST model.

    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

  5. #50
    B Reams brook.reams's Avatar
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    1983 R80ST Replace And Set Wheel Bearing Pre-Load

    Before I install new stainless steel spokes and chrome plated brass spoke nipples, I replace the front wheel bearings. The rear wheel does not have wheel bearings. Instead it is mounted directly to the rear drive. Since the rear wheel does not have an axle, there is no need for wheel bearings.

    Here is a link to the documentation on how I do this work and a short YouTube video that summarizes the procedure.



    VIDEO: 1983 BMW R80ST Replace Wheel Bearings & Set Pre-Load
    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. #51
    B Reams brook.reams's Avatar
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    1983 R80ST Refinish, Lace And True Wheels

    The R80ST has spoked wheels front and rear. In order to refinish the wheels using vapor blasting, I remove the spokes. This let me assess the condition of the spokes and spoke nipples so I can decide if I can keep most of them, or they need to be replaced.

    On the rear wheel only 17 out of 40 spokes weren't bent or rusted and only 8 spoke nipples were not damaged. On the front wheel every spoke was bent. So I replace all the spokes with stainless steel spokes and install new plated brass nipples.

    This documents how I do this work.

    And this video shows the techniques I use in more detail.



    VIDEO: 1983 BMW R80ST Lace The Spokes And True The Wheels

    Here is what I started with.

    Front Wheel-Before
    Front Wheel-Before

    Front Wheel-Before
    Front Wheel-Before

    Rear Wheel Before
    Rear Wheel Before

    Rear Wheel Before
    Rear Wheel Before

    And here is what the wheels look like after refinishing them and lacing and truing the wheels with new stainless steel spokes.

    What All Done Looks Like
    What All Done Looks Like
    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. #52
    B Reams brook.reams's Avatar
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    1983 R80ST Install Engine In The Frame

    At last, I get to start putting this motorcycle back together. Every time I install an engine in the frame it's a milestone. Instead of taking things apart, I am starting down the road to getting it all back together again :-).

    Here is a link to the documentation and the video I shot.



    VIDEO: 1983 BMW R80ST Install Engine In Frame

    I had the frame powder coated.

    Powder Coated Frame
    Powder Coated Frame

    I use some foam packing sheets to wrap the tubes so I won't ding the powder coat when I put the engine inside the frame.

    Frame Protected With Foam Sheets
    Frame Protected With Foam Sheets

    The top is off the engine so it's lighter and easier to install in the frame.

    Engine Supported With 2x4
    Engine Supported With 2x4

    Engine Inside Frame
    Engine Inside Frame

    This is the hardware used to mount the engine in the frame.

    Engine Mounting Hardware
    Engine Mounting Hardware

    It's mounted on my portable motorcycle lift ready to install the top end.

    Frame & Engine Mounted On Portable Motorcycle Lift
    Frame & Engine Mounted On Portable Motorcycle Lift
    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. #53
    B Reams brook.reams's Avatar
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    1983 R80ST Install Engine Top End

    The 1983 R80ST top end is the same as the 1983 R100RS with the exception of a smaller cylinder bore, piston and rings. I already thoroughly documented installing the engine top end for the 1983 R100RS, so I reuses a lot of that material as appropriate in the documentation and the summary video.

    Here is the document and video links.





    VIDEO: 1983 BMW R80ST Install Engine Top End

    Here is what I started with and the final result.

    The Engine Before I Removed The Top End
    The Engine Before I Removed The Top End

    The cylinders and heads were vapor blasted and I hand cleaned the engine block. I repainted the inner timing cover and top engine cover and had the frame powder coated.

    Here is the engine with the top end installed. I put shop rags in the exhaust and intake ports of the heads to prevent anything from getting inside. I also put red tape on the temporary spark plugs and on the dip stick to alert me that I need to install new plugs and oil before I start the engine.

    What All Done Looks Like
    What All Done Looks Like

    What All Done Looks Like
    What All Done Looks Like
    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. #54
    Back in the saddle again mikegalbicka's Avatar
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    Great progress and looking good!

  10. #55
    Quote Originally Posted by brook.reams View Post
    The 1983 R80ST top end is the same as the 1983 R100RS with the exception of a smaller cylinder bore, piston and rings. I already thoroughly documented installing the engine top end for the 1983 R100RS, so I reuses a lot of that material as appropriate in the documentation and the summary video.

    Here is the document and video links.





    VIDEO: 1983 BMW R80ST Install Engine Top End

    Here is what I started with and the final result.

    The Engine Before I Removed The Top End
    The Engine Before I Removed The Top End

    The cylinders and heads were vapor blasted and I hand cleaned the engine block. I repainted the inner timing cover and top engine cover and had the frame powder coated.

    Here is the engine with the top end installed. I put shop rags in the exhaust and intake ports of the heads to prevent anything from getting inside. I also put red tape on the temporary spark plugs and on the dip stick to alert me that I need to install new plugs and oil before I start the engine.

    What All Done Looks Like
    What All Done Looks Like

    What All Done Looks Like
    What All Done Looks Like
    Sir, do you take projects/complete over hauls for customers? Do you ever sell the bikes you've restored or are they all for clients?

    thanks, and great work on restoring the old gems
    The lion does not even bother to turn his head when he hears the small dog barking.

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

  11. #56
    B Reams brook.reams's Avatar
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    Quote Originally Posted by mikegalbicka View Post
    Great progress and looking good!
    Thank you mike. It's a large improvement from what I started with :-)
    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. #57
    B Reams brook.reams's Avatar
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    Quote Originally Posted by brownie0486 View Post
    Sir, do you take projects/complete over hauls for customers? Do you ever sell the bikes you've restored or are they all for clients?

    thanks, and great work on restoring the old gems
    Brownie0486,

    I'm an amature hobbyist. I don't do projects for customers. I've kept all the bikes I rebuilt except for this one which I will auction donating all the proceeds to the Motorcycle Relief Project. When I finish this one, I'll have to see what I do on the next project: try another charity build, or restore and sell. I haven't made that decision yet.

    And thank you for your kind words.
    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. #58
    Registered User slowpokepete's Avatar
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    @brook.reams hope you don't mind if I post the link to your newest video for this project.

    BTW thank you for continuing this...I find this fascinating!

    https://www.youtube.com/watch?v=LH1J_lOsC7o&t=6s

    SPP
    Member # 222067

  14. #59
    B Reams brook.reams's Avatar
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    Quote Originally Posted by slowpokepete View Post
    @brook.reams hope you don't mind if I post the link to your newest video for this project.

    BTW thank you for continuing this...I find this fascinating!

    https://www.youtube.com/watch?v=LH1J_lOsC7o&t=6s

    SPP
    Slowpokepete,

    I post all my content so it can be used. Feel free to send links to anyone who needs the info.

    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. #60
    B Reams brook.reams's Avatar
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    1983 R80ST Rebuild, Refinish Carburetors

    This bike came without any carburetors. I found a set of used 32 mm BING carburetors (64/32/323-324) after searching through a box of used carburetor's in one of Clem Cykowski's storage rooms. These are not the models used on the 1983 R80ST, but they will work. The date stamps on them indicate the 323 was manufactured in 11/1982 and the 324 was manufactured in 10/1982. I have to replace a lot of missing parts on the carburetors.

    Useable Carburetor From Clem's Used Carburetor Pile; 64/32/323-324
    Useable Carburetor From Clem's Used Carburetor Pile; 64/32/323-324

    Right Side Carburetor (64/32/324)
    Right Side Carburetor (64/32/324)

    Right Carburetor Manufacture Date (October 1982)
    Right Carburetor Manufacture Date (October 1982)

    Left Side Carburetor Number (64/32/323)
    Left Side Carburetor Number (64/32/323)

    Left Side Carburetor Manufacture Date (November 1982)
    Left Side Carburetor Manufacture Date (November 1982

    Here is how I do this work.

    Here are the before and after pictures.

    Parts Before Cleaning & Polishing
    Parts Before Cleaning & Polishing

    Parts Before Cleaning & Polishing
    Parts Before Cleaning & Polishing

    These Carburetors Use The Rubber Tipped Float Needle
    These Carburetors Use The Rubber Tipped Float Needle

    I repainted the emblems as the white paint was missing on one carburetor and pretty dull on the other.

    Rebuilt & Refinished Carburetors
    Rebuilt & Refinished Carburetors

    Finished Carburetor Rebuild-Refinish
    Finished Carburetor Rebuild-Refinish

    Finished Carburetor Rebuild-Refinish
    Finished Carburetor Rebuild-Refinish

    Finished Carburetor Rebuild-Refinish
    Finished Carburetor Rebuild-Refinish

    Finished Carburetor Rebuild-Refinish
    Finished Carburetor Rebuild-Refinish
    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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