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Thread: 1983 R80ST Rebuild For Charity Project Journal

  1. #16
    B Reams brook.reams's Avatar
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    1983 R80ST Remove The Engine From The Frame

    Now that I removed the top end, I'm ready to remove the engine from the frame.

    Engine Top End Removed
    Engine Top End Removed

    This documents how I do this work with a short YouTube video.



    VIDEO: 1983 BMW R80ST Remove The Engine From The Frame

    I put the engine on my portable motorcycle lift so I can move it around the shop.

    Engine Ready For Moving Around The Shop
    Engine Ready For Moving Around The Shop

    At this point, I have completed disassembly of the R80ST down to the frame :-)

    Frame
    Frame

    Here is how the bike looks now with all the parts packed in bins.

    Bike Disassembled With Parts In Bins
    Bike Disassembled With Parts In Bins
    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. #17
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    1983 R80ST Disassembly Down To The Frame

    This document shows how I disassemble a 1983 BMW R80ST "project bike" down to the frame.

    It has links to other documents that describe how to remove various assemblies such as the electrical system, brakes, drive train, engine etc. Although not included in this document, there will be other documents that cover details about the disassembly and rebuilding of some of the components removed in this document; e.g., the master cylinder, disk calipers, wheel bearings, etc.

    I got the bike in November 2021 as a project bike. Consequently, a number of parts were not installed on the bike so I won't be showing how to remove them. Nonetheless, I list the removal of parts in the order that I would have removed them so you can use this document as a guide for removing all the parts from the bike to strip it down to the frame.

    As Delivered To Brook's Airhead Garage
    As Delivered To Brook's Airhead Garage

    Additional Parts That Had Been Removed
    Additional Parts That Had Been Removed

    After I finished disassembling it and storing parts in bins, this is what it looks like.

    Disassembled 1983 R80ST With Parts In Bins
    Disassembled 1983 R80ST With Parts In Bins
    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. #18
    B Reams brook.reams's Avatar
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    1983 R80ST Refinish Aluminum Engine Block

    Folks,

    I get a number of questions about how I achieve the "like new" patina on the engine block, transmission and rear drive. I previously published two documents on refinishing, so on this project I decided to create a short YouTube video showing the products and tools I use and how I restore the aluminum to like new condition without bead blasting the engine block. Blasting the block requires complete disassembly and then meticulous and laborious cleaning of all the oil passages to guarantee no bits of glass are inside.

    Here is the document and YouTube video I published. The document contains links to the two documents I previously published about how I refinish various parts.




    VIDEO: 1983 BMW R80ST Refinish Aluminum Engine Block

    And here are some before and after pictures starting with what the R80ST looked like when I first saw it.

    Engine Block & Transmission When I Found The Bike
    Engine Block & Transmission When I Found The Bike

    Engine Block When I Found The Bike
    Engine Block When I Found The Bike

    Lower Left Of Engine Block When I Found The Bike
    Lower Left Of Engine Block When I Found The Bike

    Lower Left Of Engine Block When I Found The Bike
    Lower Left Of Engine Block When I Found The Bike

    Oil Pan And Bottom Of Transmission When I Found The Bike
    Oil Pan And Bottom Of Transmission When I Found The Bike

    Here is what the engine block looked like after I removed it from the frame.

    Left Side, Lower Block Still Filthy
    Left Side, Lower Block Still Filthy

    Shelf At Rear Of The Block Was Filthy With Thick Gunk I Removed With A Paint Scraper
    Shelf At Rear Of The Block Was Filthy With Thick Gunk I Removed With A Paint Scraper

    Right Side, Lower Block Still Filthy
    Right Side, Lower Block Still Filthy

    And here is the final result after working about 10 hours over 5 days on refinishing the aluminum block. Note the I have not worked on the front engine cover nor the painted oil pan. I'll get to those in time and refinish them.

    All Done-Left Side
    All Done-Left Side

    All Done-Left Side
    All Done-Left Side

    All Done-Rear
    All Done-Rear

    All Done-Right Side
    All Done-Right Side

    All Done-Right Side
    All Done-Right Side

    I hope this is helpful.
    Last edited by brook.reams; 02-17-2022 at 10:48 PM.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  4. #19
    Registered User 88bmwjeff's Avatar
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    Brook, thanks for the video regarding the engine case "cleaning". How long does the cleaning/refinishing last?
    Jeff in W.C.
    1988 R100 RT (the other woman)
    2018 R1200 GS
    "I got my motorcycle jacket but I'm walking all the time." Joe Strummer

  5. #20
    B Reams brook.reams's Avatar
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    Quote Originally Posted by 88bmwjeff View Post
    Brook, thanks for the video regarding the engine case "cleaning". How long does the cleaning/refinishing last?
    If you keep the bike washed and garaged, it will last years before the deep oxidation I found would occur, if at all. You could also apply Boeshield T9 spray to the aluminum to retard oxidation. I may do that after I finish the project.
    Last edited by brook.reams; 02-17-2022 at 10:46 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

  6. #21
    Registered User slowpokepete's Avatar
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    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
    Member # 222067

  7. #22
    Registered User PAS's Avatar
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    What is the aluminum cleaner you are using?

  8. #23
    Liaison 20774's Avatar
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    Quote Originally Posted by PAS View Post
    What is the aluminum cleaner you are using?
    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!
    Kurt -- Forum Liaison ---> Resources and Links Thread <---
    '78 R100/7 & '69 R69S & '52 R25/2
    mine-ineye-deatheah-pielayah-jooa-kalayus. oolah-minane-hay-meeriah-kal-oyus-algay-a-thaykin', buddy!

  9. #24
    B Reams brook.reams's Avatar
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    Quote Originally Posted by slowpokepete View Post
    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
    Thank you for the 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

  10. #25
    Registered User PAS's Avatar
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    Quote Originally Posted by 20774 View Post
    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!
    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.

  11. #26
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    Quote Originally Posted by PAS View Post
    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.
    Autosol.com, out of Texas.
    Dave Hutton '78 R100S (mfg 7/77)

  12. #27
    B Reams brook.reams's Avatar
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    Quote Originally Posted by PAS View Post
    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.
    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
    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. #28
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    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.



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

    Front Engine Cover Corrosion
    Front Engine Cover Corrosion

    Front Engine Cover Corrosion
    Front Engine Cover Corrosion

    Front Engine Cover Corrosion
    Front Engine Cover Corrosion

    Comparing Engine Block To Front Cover: Cover Is Has A Finer Casting So More Shine
    Comparing Engine Block To Front Cover: Cover Is Has A Finer Casting So More Shine

    I hope this information is useful.
    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. #29
    B Reams brook.reams's Avatar
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    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.

    R80ST Clutch Assembly
    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.

    I also shot a short video of the work I did on the R80ST.


    VIDEO: 1983 BMW R80ST Clutch Removal

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

    Clutch Condition-Rear Side That Faces You
    Clutch Condition-Rear Side That Faces You

    Clutch Condition-Engine Side That Faces Flywheel
    Clutch Condition-Engine Side That Faces Flywheel
    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. #30
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    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.

    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.

    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.

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



    VIDEO: 1983 BMW R80ST Remove Flywheel

    Air Impact Wrench With 19 mm Socket
    Air Impact Wrench With 19 mm Socket

    Flywheel Bolts Cover Plater
    Flywheel Bolts Cover Plater

    Flywheel Removed With Guide Ring Still On The Rear Nose Of The Crankshaft
    Flywheel Removed With Guide Ring Still On The Rear Nose Of The Crankshaft

    Nipple On Front Of Guide Ring And Groove Worn By Rear Main Seal
    Nipple On Front Of Guide Ring And Groove Worn By Rear Main Seal
    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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