1983 R80ST Rebuild For Charity Project Journal

[brook.reams]

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.

• 33 BMW 1983 R80ST Replace Swing Arm Bearings

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.

• 33 BMW 1973 R75/5 Remove & Install New Swing Arm Bearings

[brook.reams]

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.

• 11 BMW 1983 R100RS Remove Push Rod Tubes & Head Studs


• 11 BMW 1983 R100RS Install Push Rod Tubes & Head Studs

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


Original Cylinder And Push Rod Tubes

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

• 11 BMW 1983 R80ST Replace Push Rod Tubes

VIDEO: 1983 BMW R80ST Replace Push Rod Tubes

This is the final result.


New Stainless Steel Push Rod Tubes Installed In Vapor Blasted Cylinders

[slowpokepete]

Excellent, as always, Brook.

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

SPP

[brook.reams]

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]

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.

• 36 BMW 1983 R80ST Replace Wheel Bearings & Set Bearing Pre-Load

VIDEO: 1983 BMW R80ST Replace Wheel Bearings & Set Pre-Load

[brook.reams]

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.

• 36 BMW 1983 R80ST Refinish, Lace & True Wheels

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


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

[brook.reams]

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.

• 11 BMW 1983 R80ST Install Engine In The Frame

VIDEO: 1983 BMW R80ST Install Engine In Frame

I had the frame powder coated.


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

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


Engine Supported With 2x4


Engine Inside Frame

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


Engine Mounting Hardware

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


Frame & Engine Mounted On Portable Motorcycle Lift

[brook.reams]

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.

• 11 BMW 1983 R80ST Install Engine Top End

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 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

[mikegalbicka]

Great progress and looking good!

[brownie0486]

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.

• 11 BMW 1983 R80ST Install Engine Top End

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 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

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

[brook.reams]

Great progress and looking good!

Thank you mike. It's a large improvement from what I started with :-)

[brook.reams]

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.

[slowpokepete]

@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

[brook.reams]

@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]

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


Right Side Carburetor (64/32/324)


Right Carburetor Manufacture Date (October 1982)


Left Side Carburetor Number (64/32/323)


Left Side Carburetor Manufacture Date (November 1982

Here is how I do this work.

• 13 BMW 1983 R80ST Rebuild, Refinish Carburetors

Here are the before and after pictures.


Parts Before Cleaning & Polishing


Parts Before Cleaning & Polishing


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


Finished Carburetor Rebuild-Refinish


Finished Carburetor Rebuild-Refinish


Finished Carburetor Rebuild-Refinish


Finished Carburetor Rebuild-Refinish