1983 R80ST Rebuild For Charity Project Journal

Brook, I look forward to your new posts on this thread every time I visit the forum!

I own a 1984 R80ST, currently waiting to have pushrod seals done next month by a local BMW guy. Despite watching and re-watching your videos, I don't really have the confidence / experience / nerve to attempt the repair myself. I wish I did, and am somewhat envious of folks who do.

When my bike is all back together, I will definitely work on cleaning up the aluminum block using the methods you described in your video.

And, despite me not attempting the repair myself, the learning I have experienced by watching your extremely informative videos have been invaluable to me in understanding how my bike works.

Thanks,

SPP

What is the aluminum cleaner you are using?

PAS said:

What is the aluminum cleaner you are using?

Click to expand...

Check the first couple of minutes of his video. It looks like he uses a staging of items, first degreasing/degunking, and then ends up using Autosol. And a lot of elbow grease as well!

slowpokepete said:

Brook, I look forward to your new posts on this thread every time I visit the forum!

I own a 1984 R80ST, currently waiting to have pushrod seals done next month by a local BMW guy. Despite watching and re-watching your videos, I don't really have the confidence / experience / nerve to attempt the repair myself. I wish I did, and am somewhat envious of folks who do.

When my bike is all back together, I will definitely work on cleaning up the aluminum block using the methods you described in your video.

And, despite me not attempting the repair myself, the learning I have experienced by watching your extremely informative videos have been invaluable to me in understanding how my bike works.

Thanks,

SPP

Click to expand...

Thank you for the kind words.

20774 said:

Check the first couple of minutes of his video. It looks like he uses a staging of items, first degreasing/degunking, and then ends up using Autosol. And a lot of elbow grease as well!

Click to expand...

Thanks, I completely missed that! He done a beautiful job!

Now, where do you buy the cleaner? Autosol Multi-Purpose Metal Cleaner 500ml - 1900 Havent found it doing a search except for Australia.

PAS said:

Thanks, I completely missed that! He done a beautiful job!

Now, where do you buy the cleaner? Autosol Multi-Purpose Metal Cleaner 500ml - 1900 Havent found it doing a search except for Australia.

Click to expand...

Autosol.com, out of Texas.

PAS said:

Thanks, I completely missed that! He done a beautiful job!

Now, where do you buy the cleaner? Autosol Multi-Purpose Metal Cleaner 500ml - 1900 Havent found it doing a search except for Australia.

Click to expand...

I included a link to the product in my documentation in the "Tools" section. To save you looking for it:
--> http://www.autosol.com/product_p/1800.htm

1983 R80ST Repair, Refinish, Paint

I published this document to show how I repair, refinish and paint parts on this project. It contains links to other documents as well as original material. I will be adding to it as I progress with the project.

• 51 BMW R80ST Repair, Refinish & Paint
  

I just added how I refinished the front engine cover that had a lot of heavy corrosion on it.

<a title="Front Engine Cover Corrosion" href="https://www.flickr.com/photos/brook-reams/51891063277/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51891063277_4c89ba444a_z.jpg" alt="Front Engine Cover Corrosion" width="640" height="480" /></a>
Front Engine Cover Corrosion

<a title="Front Engine Cover Corrosion" href="https://www.flickr.com/photos/brook-reams/51892361114/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51892361114_a00e3f37f1_z.jpg" alt="Front Engine Cover Corrosion" width="640" height="480" /></a>
Front Engine Cover Corrosion

<a title="Front Engine Cover Corrosion" href="https://www.flickr.com/photos/brook-reams/51892108723/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51892108723_5d19bb1c68_z.jpg" alt="Front Engine Cover Corrosion" width="640" height="480" /></a>
Front Engine Cover Corrosion

<a title="Comparing Engine Block To Front Cover: Cover Is Has A Finer Casting So More Shine" href="https://www.flickr.com/photos/brook-reams/51893181498/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51893181498_3c5e028b7e_z.jpg" alt="Comparing Engine Block To Front Cover: Cover Is Has A Finer Casting So More Shine" width="640" height="480" /></a>
Comparing Engine Block To Front Cover: Cover Is Has A Finer Casting So More Shine

I hope this information is useful.

1983 R80ST Remove Clutch

The clutch in this 1983 R80ST is the same as the one used in the 1983 R100RS that I rebuilt and converted to an RT model. You can see the procedure I used to remove the 1983 R100RS clutch here.
<ul class="children">
<li class="page_item page-item-7378"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/21-bmw-1983-r100rs-remove-clutch/">21 BMW 1983 R100RS Remove Clutch</a></li>
</ul>
<a title="R80ST Clutch" href="https://www.flickr.com/photos/brook-reams/51904948070/in/album-72177720296961644/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51904948070_53332f4a6e_c.jpg" alt="R80ST Clutch Assembly" width="800" height="600" /></a>
R80ST Clutch Assembly

I summarize what I found on the 1993 R80ST in this document, which has links to sections of the 1983 R100RS clutch removal document.
<ul class="children">
<li class="page_item page-item-9900"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/21-bmw-r80st-remove-clutch/">21 BMW R80ST Remove Clutch</a></li>
</ul>
I also shot a short video of the work I did on the R80ST.

<strong>VIDEO: <em>1983 BMW R80ST Clutch Removal</em></strong>

The clutch was a bit rusty and grungy. I plan to replace it with one donated to me by Euro MotoElectrics.

<a title="Clutch Condition-Rear Side That Faces You" href="https://www.flickr.com/photos/brook-reams/51904306821/in/album-72177720296961644/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51904306821_2dcc1d4f87_c.jpg" alt="Clutch Condition-Rear Side That Faces You" width="800" height="600" /></a>
Clutch Condition-Rear Side That Faces You

<a title="Clutch Condition-Engine Side" href="https://www.flickr.com/photos/brook-reams/51904392958/in/album-72177720296961644/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51904392958_f4c2993cda_c.jpg" alt="Clutch Condition-Engine Side That Faces Flywheel" width="800" height="600" /></a>
Clutch Condition-Engine Side That Faces Flywheel

1983 R80ST Remove Flywheel

As I plan to replace the rear main seal, that is the rear oil seal on the crankshaft, inspect the oil pump and replace the oil pump cover O-ring, I need to remove the flywheel. On 1981 model year (the 1981 model year started in September 1980) and later models, the flywheel is also called the "Clutch Housing", (part# 21 21 1 338 722).

I previously removed the airbox, transmission and the clutch so I can access the flywheel. You can see how I do that work here.
<ul class="children">
<li class="page_item page-item-9755"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/13-bmw-r80st-remove-air-box-pulse-air-system/">13 BMW 1983 R80ST Remove Air Box & Pulse Air System</a></li>
<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-9900"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/21-bmw-r80st-remove-clutch/">21 BMW 1983 R80ST Remove Clutch</a></li>
</ul>
The flywheel on the 1981 and later models (the 1981 model year started in September 1980) is different from the earlier models. It is lighter, for one thing and is mounted differently on the rear nose of the crankshaft. The procedure for removing the earlier flywheels (before September 1980) is different as shown in these documents.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1977-bmw-r100rs-rebuild-project-index/11-bmw-1977-r100rs-replace-rear-main-seal-oil-pump-cover-o-ring/#Remove_the_Flywheel" target="_blank" rel="noopener">Remove the Flywheel (1977 R100RS)</a></li>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1973-bmw-r755-rebuild-project/11-bmw-r755-remove-replace-flywheel-rear-main-seal-oil-pump-cover-cover-o-ring/#Remove_the_Flywheel" target="_blank" rel="noopener">Remove the Flywheel (1973 R75/5)</a></li>
</ul>
The flywheel on the 1983 R80ST is the same as the one on the 1983 R100RS. I show how I removed the R100RS flywheel here. I'll link to sections of this document as appropriate.
<ul class="children">
<li class="page_item page-item-7390"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-bmw-1983-r100rs-remove-flywheel-rear-main-seal/">11 BMW 1983 R100RS Remove Flywheel & Rear Main Seal</a></li>
</ul>
Here is a link to a document showing how I do this work and a video summary.
<ul class="children">
<li class="page_item page-item-9918"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-remove-flywheel/">11 BMW 1983 R80ST Remove Flywheel</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Remove Flywheel</em></strong>

<a title="Air Impact Wrench With 19 mm Socket" href="https://www.flickr.com/photos/brook-reams/51911826757/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51911826757_255ddd630b_c.jpg" alt="Air Impact Wrench With 19 mm Socket" width="800" height="450" /></a>
Air Impact Wrench With 19 mm Socket

<a title="Flywheel Bolts Cover Plater" href="https://www.flickr.com/photos/brook-reams/51911797692/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51911797692_a9b9de1f87_c.jpg" alt="Flywheel Bolts Cover Plater" width="800" height="600" /></a>
Flywheel Bolts Cover Plater

<a title="Flywheel Removed With Guide Ring Still On The Rear Nose Of The Crankshaft" href="https://www.flickr.com/photos/brook-reams/51911797632/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51911797632_6456bdc963_c.jpg" alt="Flywheel Removed With Guide Ring Still On The Rear Nose Of The Crankshaft" width="800" height="600" /></a>
Flywheel Removed With Guide Ring Still On The Rear Nose Of The Crankshaft

<a title="Nipple On Front Of Guide Ring" href="https://www.flickr.com/photos/brook-reams/51912857133/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51912857133_626909ee3b_c.jpg" alt="Nipple On Front Of Guide Ring And Groove Worn By Rear Main Seal" width="800" height="600" /></a>
Nipple On Front Of Guide Ring And Groove Worn By Rear Main Seal

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.

<a title="Left Side View" href="https://www.flickr.com/photos/brook-reams/51729834326/in/album-72157720265271480/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51729834326_f30afa0330_c.jpg" alt="What The 1983 R80ST Looked Like When I Found It" width="800" height="600" /></a>
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.

• 12 BMW R80ST Remove And Test Starter Motor

<strong>VIDEO: <em>1983 BMW R80ST Remove And Test Starter Motor</em></strong>

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.

<a title="Starter Motor Nose Refinished" href="https://www.flickr.com/photos/brook-reams/51921237962/in/album-72177720295588903/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51921237962_d36af86dab_c.jpg" alt="Starter Motor Nose Refinished" width="800" height="600" /></a>
Starter Motor Nose Refinished

<a title="Front Starter Motor Bracket Refinished" href="https://www.flickr.com/photos/brook-reams/51922208116/in/album-72177720295588903/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51922208116_3c83858032_c.jpg" alt="Front Starter Motor Bracket Refinished" width="800" height="600" /></a>
Front Starter Motor Bracket Refinished

<a title="Top Engine Housing Is Clean" href="https://www.flickr.com/photos/brook-reams/51923010030/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51923010030_ee191b3009_c.jpg" alt="Top Engine Housing Is Clean" width="800" height="600" /></a>
Top Engine Housing Is Clean

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.
<ul class="children">
<li class="page_item page-item-9755"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/13-bmw-r80st-remove-air-box-pulse-air-system/">13 BMW 1983 R80ST Remove Air Box & Pulse Air System</a></li>
<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-9900"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/21-bmw-r80st-remove-clutch/">21 BMW 1983 R80ST Remove Clutch</a></li>
<li class="page_item page-item-9918"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-remove-flywheel/">11 BMW 1983 R80ST Remove Flywheel</a></li>
</ul>
I've published documents on removing, inspecting and installing the oil pump on other projects. Here are links to those documents.
<ul>
<li class="page_item page-item-4715 current_page_item"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1977-bmw-r100rs-rebuild-project-index/11-bmw-1977-r100rs-replace-rear-main-seal-oil-pump-cover-o-ring/">11 BMW 1977 R100RS Replace Rear Main Seal & Oil Pump Cover O-Ring</a></li>
<li class="page_item page-item-7400"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-bmw-1983-r100rs-remove-inspect-oil-pump/">11 BMW 1983 R100RS Remove & Inspect Oil Pump</a></li>
<li class="page_item page-item-7396"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-1983-bmw-r100rs-install-rear-main-seal-oil-pump-cover-o-ring-flywheel/">11 BMW 1983 R100RS Install Rear Main Seal, Oil Pump Cover & O-ring</a></li>
</ul>
Here is the link to how I do the work on the 1983 R80ST.
<ul class="children">
<li class="page_item page-item-9995"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-remove-inspect-install-oil-pump/">11 BMW 1983 R80ST Remove, Inspect, Install Oil Pump</a></li>
</ul>
And, here is a short video that summarizes how I do this work.


<strong>VIDEO: <em>1983 BMW R80ST Remove And Inspect Oil Pump</em></strong>

<a title="Oil Pump Cover Removed" href="https://www.flickr.com/photos/brook-reams/51953021383/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51953021383_6c5befaf64_z.jpg" alt="Oil Pump Cover Removed" width="640" height="480" /></a>
Oil Pump Cover Removed

<a title="Oil Pump Rotors Marked With "F" For Front Face" href="https://www.flickr.com/photos/brook-reams/51953548520/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51953548520_1e071fe611_z.jpg" alt="Oil Pump Rotors Marked With "F" For Front Face" width="640" height="480" /></a>
Oil Pump Rotors Marked With "F" For Front Face

<a title="Oil Pump Measurements" href="https://www.flickr.com/photos/brook-reams/51953792865/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51953792865_85157218a4_z.jpg" alt="Oil Pump Measurements - They Are All Good" width="640" height="178" /></a>
Oil Pump Measurements - They Are All Good

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.
<ul class="children">
<li class="page_item page-item-9755"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/13-bmw-r80st-remove-air-box-pulse-air-system/">13 BMW 1983 R80ST Remove Air Box & Pulse Air System</a></li>
<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-9900"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/21-bmw-r80st-remove-clutch/">21 BMW 1983 R80ST Remove Clutch</a></li>
<li class="page_item page-item-9918"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-remove-flywheel/">11 BMW 1983 R80ST Remove Flywheel</a></li>
</ul>
I've published documents on replacing the rear main seal on other projects. Here are links to those documents.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-bmw-1983-r100rs-remove-flywheel-rear-main-seal/" target="_blank" rel="noopener">11 BMW 1983 R100RS Remove Flywheel & Rear Main Seal</a></li>
<li class="page_item page-item-7396"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-1983-bmw-r100rs-install-rear-main-seal-oil-pump-cover-o-ring-flywheel/">11 BMW 1983 R100RS Install Rear Main Seal, Oil Pump Cover & O-ring</a></li>
<li class="page_item page-item-4715"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1977-bmw-r100rs-rebuild-project-index/11-bmw-1977-r100rs-replace-rear-main-seal-oil-pump-cover-o-ring/">11 BMW 1977 R100RS Replace Rear Main Seal & Oil Pump Cover O-Ring</a></li>
<li class="page_item page-item-4148"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1975-r756-build-s-replica/11-bmw-r756-replace-crankshaft-rear-oil-seal-oil-pump-cover-o-ring/">11 BMW 1975 R75/6 Replace Crankshaft Rear Oil Seal, Oil Pump Cover & O-ring</a></li>
<li class="page_item page-item-2270"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1973-bmw-r755-rebuild-project/11-bmw-r755-remove-replace-flywheel-rear-main-seal-oil-pump-cover-cover-o-ring/">11 BMW 1973 R75/5 Remove & Install Flywheel, Replace Rear Main Seal, Oil Pump Cover & Cover O-Ring</a></li>
</ul>
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.
<ul class="children">
<li class="page_item page-item-9927"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-replace-rear-main-seal/">11 BMW 1983 R80ST Replace Rear Main Seal</a></li>
</ul>
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.

<a title="Cycle Works Rear Main Seal Tool" href="https://www.flickr.com/photos/brook-reams/48945409542/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/48945409542_0e17dd78f1_z.jpg" alt="Cycle Works Rear Main Seal Tool" width="640" height="480" /></a>
Cycle Works Rear Main Seal Tool

<a title="Using Seal Puller To Remove Rear Main Seal" href="https://www.flickr.com/photos/brook-reams/51946717568/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51946717568_1bb37939e6_z.jpg" alt="Using Hook Seal Puller To Remove Rear Main Seal" width="640" height="480" /></a>
Using Hook Seal Puller To Remove Rear Main Seal

<a title="Verify Seal Is Flush With Case" href="https://www.flickr.com/photos/brook-reams/51954638481/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51954638481_96a8d901fa_c.jpg" alt="Using Flashlight To Verify Seal Is Flush With Case" width="800" height="600" /></a>
Using Flashlight To Verify Seal Is Flush With Case

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.
<ul class="children">
<li class="page_item page-item-9755"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/13-bmw-r80st-remove-air-box-pulse-air-system/">13 BMW 1983 R80ST Remove Air Box & Pulse Air System</a></li>
<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-9900"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/21-bmw-r80st-remove-clutch/">21 BMW 1983 R80ST Remove Clutch</a></li>
</ul>
I also show how to remove the flywheel here.
<ul class="children">
<li class="page_item page-item-9918"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-remove-flywheel/">11 BMW 1983 R80ST Remove Flywheel</a></li>
</ul>
I've published documents on removing and installing the flywheel on other projects. You can see those documents here.
<ul class="children">
<li class="page_item page-item-2270"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1973-bmw-r755-rebuild-project/11-bmw-r755-remove-replace-flywheel-rear-main-seal-oil-pump-cover-cover-o-ring/">11 BMW 1973 R75/5 Remove & Install Flywheel, Replace Rear Main Seal, Oil Pump Cover & Cover O-Ring</a></li>
<li class="page_item page-item-4715 current_page_item"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1977-bmw-r100rs-rebuild-project-index/11-bmw-1977-r100rs-replace-rear-main-seal-oil-pump-cover-o-ring/">11 BMW 1977 R100RS Replace Rear Main Seal & Oil Pump Cover O-Ring</a>
<ul class="children">
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1977-bmw-r100rs-rebuild-project-index/11-bmw-1977-r100rs-replace-rear-main-seal-oil-pump-cover-o-ring/#Remove_the_Flywheel">Remove the Flywheel</a></li>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1977-bmw-r100rs-rebuild-project-index/11-bmw-1977-r100rs-replace-rear-main-seal-oil-pump-cover-o-ring/#Install_Flywheel">Install Flywheel</a></li>
</ul>
<li class="page_item page-item-7390"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-bmw-1983-r100rs-remove-flywheel-rear-main-seal/">11 BMW 1983 R100RS Remove Flywheel & Rear Main Seal</a></li>
<li class="page_item page-item-7717"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-1983-bmw-r100rs-install-the-flywheel/">11 BMW 1983 R100RS Install The Flywheel</a></li>
</ul>
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.
<ul class="children">
<li class="page_item page-item-10015"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-install-flywheel/">11 BMW 1983 R80ST Install Flywheel</a></li>
</ul>
Here is a short YouTube video showing how I do this work.


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

Here is how things look now.

<a title="Flywheel Installed" href="https://www.flickr.com/photos/brook-reams/51954954934/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51954954934_0f9d049813_c.jpg" alt="Flywheel Installed" width="800" height="600" /></a>
Flywheel Installed

Very impressive sir, thanks for all the sharing and knowledge you bring to the group

brownie0486 said:

Very impressive sir, thanks for all the sharing and knowledge you bring to the group

Click to expand...

You're welcome brownie0486.

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 <a href="https://www.motorelief.org/" target="_blank" rel="noopener">Motorcycle Relief Project</a>.

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

• 21 BMW 1983 R80ST Install Clutch

I also shot a short video summarizing the work.


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

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

<a title="R80ST Clutch" href="https://www.flickr.com/photos/brook-reams/51904948070/in/album-72177720296961644/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51904948070_53332f4a6e_c.jpg" alt="Original R80ST Clutch" width="800" height="600" /></a>
Original R80ST Clutch Looks Very Bedraggled

<a title="Clutch Condition-Rear Side That Faces You" href="https://www.flickr.com/photos/brook-reams/51904306821/in/album-72177720296961644/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51904306821_2dcc1d4f87_c.jpg" alt="Original Clutch Condition" width="800" height="600" /></a>
Original Clutch Condition

<a title="Clutch Pack Assembled For Installation On Face Of Flywheel" href="https://www.flickr.com/photos/brook-reams/51959175483/in/album-72177720296961644/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51959175483_d6145f3415_c.jpg" alt="New EME Supplied Clutch Pack Assembled For Installation On Face Of Flywheel" width="800" height="600" /></a>
New EME Supplied Clutch Pack Assembled For Installation On Face Of Flywheel

<a title="Clutch Installed" href="https://www.flickr.com/photos/brook-reams/51959566044/in/album-72177720296961644/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51959566044_ac057ce704_c.jpg" alt="New Clutch Installed" width="800" height="600" /></a>
New Clutch Installed

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.

<a title="Original Alternator" href="https://www.flickr.com/photos/brook-reams/51970020603/in/album-72177720297720977/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51970020603_4286b1e804_c.jpg" alt="Original Alternator Looks Bedraggled" width="800" height="600" /></a>
Original Alternator Looks Bedraggled

I've replaced charging systems on other projects. Here are links to those documents.
<ul class="children">
<li class="page_item page-item-4498"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1977-bmw-r100rs-rebuild-project-index/12-bmw-1977-r100rs-replace-engine-electrical-components/">12 BMW 1977 R100RS Replace Engine Electrical Components</a></li>
<li class="page_item page-item-6734"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/12-bmw-1983-r100rs-remove-diode-board-alternator-electronic-ignition-sensor/">12 BMW 1983 R100RS Remove Diode Board, Alternator & Electronic Ignition Sensor</a></li>
</ul>
Here is what the inner timing cover looks like after all the engine electrical components are removed.

<a title="Inner Timing Cover After Engine Electrical Components Removed" href="https://www.flickr.com/photos/brook-reams/51972829600/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51972829600_a39b455bc3_c.jpg" alt="Inner Timing Cover After Engine Electrical Components Removed" width="800" height="600" /></a>
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.
<ul class="children">
<li class="page_item page-item-10066"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/12-bmw-1983-r80st-remove-alternator-diode-board-electronic-ignition-sensor/">12 BMW 1983 R80ST Remove Alternator, Diode Board & Electronic Ignition Sensor</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Remove Alternator, Diode Board & Electronic Ignition Sensor</em></strong>

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:
<ul class="children">
<li class="page_item page-item-9890"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/51-bmw-r80st-repair-refinish-paint/">51 BMW 1983 R80ST Repair, Refinish & Paint</a>
<ul class="children">
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/51-bmw-r80st-repair-refinish-paint/#Paint_Inner_Timing_Cover">Paint Inner Timing Cover</a></li>
</ul></li></ul>
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.
<ul class="children">
<li class="page_item page-item-10077"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-replace-timing-chain-crankshaft-sprocket-nose-bearing/">11 BMW 1983 R80ST Replace Timing Chain, Crankshaft Sprocket & Nose Bearing</a></li>


<strong>VIDEO: <em>1983 BMW R80ST Remove Timing Chain, Crankshaft Sprocket & Nose Bearing</em></strong>

• <strong>VIDEO: 1983 BMW R80ST <em>Install Crankshaft Sprocket And Nose Bearing</em></strong>
• <strong>VIDEO: <em>1983 BMW R80ST Install Timing Chain</em></strong>
• <strong>VIDEO: <em>1983 BMW R80ST Install Inner Timing Cover</em></strong>

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 <a href="http://vintagetwins.com/" target="_blank" rel="noopener">Vintage Twins</a>, 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 <a href="https://www.motorelief.org/" target="_blank" rel="noopener">Motorcycle Relief Project</a>, they generously provided me a nice discount on the work.

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

<a title="The Orange Oil Pan" href="https://www.flickr.com/photos/brook-reams/52035201725/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52035201725_63eff2fd30_c.jpg" alt="The Original Orange Oil Pan" width="800" height="450" /></a>
The Original Orange Oil Pan

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52033644282/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52033644282_e0d554ba78_c.jpg" alt="All Done With Vapor Blasted Oil Pan" width="800" height="600" /></a>
All Done With Vapor Blasted Oil Pan

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/52034728053/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/52034728053_87386a4a78_c.jpg" alt="All Done With Vapor Blasted Oil Pan" width="800" height="600" /></a>
All Done With Vapor Blasted Oil Pan

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

<li class="page_item page-item-10166"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-replace-oil-pan-oil-pump-suction-flange-gaskets/">11 BMW 1983 R80ST Replace Oil Pan & Oil Pump Suction Flange Gaskets</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Replace Oil Pan and Oil Pump Suction Flange Gasket</em></strong>