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1983 R80ST Rebuild For Charity Project Journal

brook.reams

B Reams
I have just started a new project at "Brook's Airhead Garage", a rebuild of a 1983 R80ST for charity. When I complete the project I will auction the bike and all proceeds will go to a charity, The Motorcycle Relief Project, that uses motorcycle rides to help military and first responders cope with PTSD.

This is what I am starting with.

<a title="Delivered To Brook's Airhead Garage" href="https://www.flickr.com/photos/brook-reams/51730769380/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/51730769380_a6f7af5588_c.jpg" alt="1983 R80ST As Delivered To Brook's Airhead Garage" width="800" height="600" /></a>
1983 R80ST As Delivered To Brook's Airhead Garage

And this is what my target is when I'm done.

<a title="R80ST-Silver" href="https://www.flickr.com/photos/brook-reams/51732200798/in/album-72157720265271480/" target="_blank" rel="noopener" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/51732200798_976ef72122_c.jpg" alt="The Target For My Rebuild, R80ST In Metallic Silver Livery" width="800" height="503" /></a>
The Target For My Rebuild, R80ST In Metallic Silver Livery

I contacted Euro MotoElectrics about this project and they have generously offered to supply parts from their inventory at no charge as they have been supporting the Motorcycle Relief Project. That is awesome generosity for a worthy cause.

I have posted the initial pre-build inspection and high level project plan on my website along with a short YouTube video of the inspection on my YouTube channel, "Brook's Airhead Garage".




YouTube Video: 1983 BMW R80ST Pre-build Inspection

I also started the project index page that contains links to all the documentation I publish on the project. It includes some background on the provenance of this bike. I update this page as I post new documents about my work.

I hope this is helpful.
 
Looking forward

Well Brook, like all of your projects, I look forward to following the progress and viewing/reading the excellent videos and reports you produce on the side. If I were closer, I would offer a hand to help. St.
 
What a neat project for a worthy cause. Best of luck. Will be following your progress with eager anticipation of the final result.
 
1983 R80ST Remove Electrical System

This bike is a "project bike" so some of the electrical components are missing. That makes it quicker to remove the electrical system. :)

<a title="Delivered To Brook's Airhead Garage" href="https://www.flickr.com/photos/brook-reams/51730769380/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51730769380_a6f7af5588_c.jpg" alt="1983 R80ST As Delivered To Brook's Airhead Garage" width="800" height="600" /></a>
1983 R80ST As Delivered To Brook's Airhead Garage

I show how I removed the electrical system in this document.
<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>
I also made a short video overview of the R80ST electrical system


<em><strong>VIDEO: 1983 BMW R80ST Electrical System Overview</strong></em>

Here is the main wiring harness I removed after I disconnected it from the electrical components and various sub-harnesses that I also removed.

<a title="Main Wiring Harness Cluster Of Relay Sockets" href="https://www.flickr.com/photos/brook-reams/51794414106/in/album-72177720295588903/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51794414106_a3475a1898_c.jpg" alt="Main Wiring Harness After Removing Under The Gas Tank Electrical Components" width="800" height="600" /></a>
Main Wiring Harness After Removing Under The Gas Tank Electrical Components

<a title="Main Wiring Harness Removed" href="https://www.flickr.com/photos/brook-reams/51794413936/in/album-72177720295588903/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51794413936_9cd80d0d8d_c.jpg" alt="Main Wiring Harness Removed" width="600" height="800" /></a>
Main Wiring Harness Removed

It's good to get back into the swing of things on another rebuild project. ;)
 
1983 R80ST Remove Center Stand, Crash Bars and Side Stand

I'm making progress on the disassembly of this project bike. That said, a lot was already removed, so this one isn't taking me as long. :)

<a title="Delivered To Brook's Airhead Garage" href="https://www.flickr.com/photos/brook-reams/51730769380/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51730769380_a6f7af5588_c.jpg" alt="As Delivered To Brook's Airhead Garage With Some Parts Missing" width="800" height="600" /></a>
As Delivered To Brook's Airhead Garage With Some Parts Missing

<a title="Delivered To Brook's Airhead Garage" href="https://www.flickr.com/photos/brook-reams/51730769355/in/album-72157720265271480/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51730769355_a5bb1fa3af_c.jpg" alt="As Delivered To Brook's Airhead Garage" width="800" height="600" /></a>
As Delivered To Brook's Airhead Garage

The left crash bar includes a bracket for the side stand instead of mounting it on a bracket that's part of the front engine mount stud.

<a title="Left Crash Bar With Side Stand Removed" href="https://www.flickr.com/photos/brook-reams/51813148621/in/album-72177720295825079/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51813148621_c1c93f813a_c.jpg" alt="Left Crash Bar With Side Stand" width="800" height="600" /></a>
Left Crash Bar With Side Stand

<a title="Side Stand Mounting Detail In Left Crash Bar" href="https://www.flickr.com/photos/brook-reams/51815171284/in/album-72177720295825079/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51815171284_d7a73c0e27_c.jpg" alt="Side Stand Mounting Detail In Left Crash Bar" width="800" height="600" /></a>
Side Stand Mounting Detail In Left Crash Bar

Here's a link to the documentation of how I did this work.
<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>
 
 
1983 R80ST Remove Front Suspension

After I removed the wheels and the handlebar, I'm ready to remove the front suspension: the front forks, the steering stem nut, top plate, steering head bearings pre-load adjuster nut and the steering stem with the attached lower triple clamp.

<a title="Bike After Wheels Removed" href="https://www.flickr.com/photos/brook-reams/51816348272/in/album-72177720295944273/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51816348272_7c1b638671_c.jpg" alt="Bike After Wheels Removed And Ready To Remove The Front Suspension" width="800" height="600" /></a>
Bike After Wheels Removed And Ready To Remove The Front Suspension

You can read about how I do this work here:
<ul class="children">
<li class="page_item page-item-9713"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/31-bmw-1983-r80st-remove-front-suspension/">31 BMW 1983 R80ST Remove Front Suspension</a></li>
</ul>
And here is a short YouTube video that summarizes how I do this work.


<em><strong>VIDEO: 1983 BMW R80ST Charity Build: Remove Front Suspension</strong></em>

Here's the bike after I removed the front suspension.

<a title="Front Suspension Removed" href="https://www.flickr.com/photos/brook-reams/51820537336/in/album-72177720295944273/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51820537336_6d7ef0f5d6_c.jpg" alt="Bike After Wheels Removed And Ready To Remove The Front Suspension" width="800" height="600" /></a>
Bike After Wheels Removed And Ready To Remove The Front Suspension
 
Work

LOL, Brook, I have always found removing things to be a cake walk. It is the reverse that caused me on my RT project last winter to refer numerous times to your videos on your RT project. St.
 
1983 R80ST Remove Rear Drive, Swing Arm, Monoshock

After completing this work, most of the disassembly down to the frame is complete as I also removed the rear sub-frame and muffler that is attached to it.

<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="Rear Drive, Swing Arm & Rear Monoshock" width="800" height="600" /></a>
Rear Drive, Swing Arm & Rear Monoshock

<a title="Rear Sub-Frame Detail" href="https://www.flickr.com/photos/brook-reams/51830967021/in/album-72177720295825079/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51830967021_84366d9c14_c.jpg" alt="Rear Sub-Frame Removed" width="800" height="600" /></a>
Rear Sub-Frame Removed

<a title="Muffler Removed" href="https://www.flickr.com/photos/brook-reams/51830016832/in/album-72177720295825079/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51830016832_819ef92a91_c.jpg" alt="Muffler Removed" width="800" height="600" /></a>
Muffler Removed

<a title="Down To The Engine, Transmission and Frame" href="https://www.flickr.com/photos/brook-reams/51831693075/in/album-72177720295825079/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51831693075_5e7f14cc31_c.jpg" alt="Down To The Air Box, Transmission, Engine and Frame" width="800" height="600" /></a>
Down To The Air Box, Transmission, Engine and Frame

All I have left to do is remove the air box, transmission and the engine from the frame.

You can read about how I do this work and watch a short YouTube video summarizing the work here.
<ul class="children">
<li class="page_item page-item-9734"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/33-1983-bmw-r80st-remove-rear-drive-swing-arm-monoshock/">33 1983 BMW R80ST Remove Rear Drive, Swing Arm, Monoshock</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Remove Rear Drive, Swing Arm & Monoshock</em></strong>
 
1983 R80ST Remove Air Box and Pulse Air System

The air box is secured to the top of the transmission. Inside are components for the crankcase rebreather system and for the Pulse Air System which is a passive system designed to reduce emissions to meet the US standards in the early to mid-1980's.

<a title="Air Box With Pulse Air Components" href="https://www.flickr.com/photos/brook-reams/51734200103/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51734200103_cee0f0b0b8_c.jpg" alt="Air Box With Pulse Air And Crankcase Rebreather Components-And Some Leaves" width="800" height="600" /></a>
Air Box With Pulse Air And Crankcase Rebreather Components-And Some Leaves

<span style="color: #0000ff;"><span style="text-decoration: underline;"><strong>NOTE</strong></span>:</span>
<span style="color: #0000ff;">The picture was taken when I first saw the bike and the air box cover was missing. Leaves are not part of the crankcase rebreather or pulse air system inside the air box. :)</span>

The Pulse Air System is a passive system with no active motors or moving parts. It sucks filtered air into the exhaust manifold in the heads to help burn any gasoline and to ensure CO emissions are converted to CO2. That said, according to <a href="http://bmwmotorcycletech.info/pulseair.htm" target="_blank" rel="noopener noreferrer">Bob Fleischer's information on the Pulse Air system</a>, this increases the exhaust gas temperature and likely exacerbates wear of the valves and seats and could contribute to warped heads. The original valves and seats in 1983 had problems with valve recession due to excessive wear from the metallurgy BMW used to try and compensate for unleaded fuel.

For these reasons, I'm going to update the Pulse Air system and modify the air box so the valve train stays nice and cool. I will purchase a smog kit from <a href="http://www.rubberchickenracinggarage.com/" target="_blank" rel="noopener noreferrer">Rubber Chicken Racing Garage</a> that has all the parts needed to complete this upgrade.

Here is the documentation of how I do this work and a short YouTube video summarizing the procedure.
<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 R80ST Remove Air Box & Pulse Air System</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Remove Air Box & Pulse Air System</em></strong>

I'm ready to remove the transmission and the engine from the frame.
 
1983 R80ST Remove Transmission

The transmission on this 1983 R80ST is serial number Z 078854. According to <a href="https://bmwmotorcycletech.info/transmission.htm" target="_blank" rel="noopener">Robert Fleischer's article on transmissions</a>, the range of transmission serial numbers in 1983 was from Z 074700 to Z 084299, so mine is the original transmission as it is within the range for 1983.

<a title="Transmission Serial Number" href="https://www.flickr.com/photos/brook-reams/51842163035/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51842163035_09a073cf8e_c.jpg" alt="Transmission Serial Number Z 078854" width="800" height="600" /></a>
Transmission Serial Number Z 078854

I removed the transmission after removing the battery and battery box, the rear drive, swing arm and monoshock, and the air box and the pulse air and crankcase rebreather components.

<a title="Battery Box Removed" href="https://www.flickr.com/photos/brook-reams/51808822863/in/album-72177720295825079/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51808822863_e6c4062782_c.jpg" alt="Battery Box Removed" width="800" height="600" /></a>
Battery Box Removed

<a title="Rear Drive, Monoshock & Swing Arm Removed" href="https://www.flickr.com/photos/brook-reams/51831667700/in/album-72177720296079745/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51831667700_33999830c8_c.jpg" alt="Rear Drive, Monoshock & Swing Arm Removed" width="800" height="600" /></a>
Rear Drive, Monoshock & Swing Arm Removed

<a title="Air Box With Pulse Air Components" href="https://www.flickr.com/photos/brook-reams/51734200103/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51734200103_cee0f0b0b8_c.jpg" alt="Air Box With Pulse Air And Crankcase Rebreather Components" width="800" height="600" /></a>
Air Box With Pulse Air And Crankcase Rebreather Components

<a title="Battery Box Removed" href="https://www.flickr.com/photos/brook-reams/51840462417/in/dateposted-public/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51840462417_14b35de3f9_c.jpg" alt="Air Box Removed" width="800" height="450" /></a>
Air Box Removed

I found water in the transmission gear lube. The speedometer cable was missing and the hole in the bushing for the cable was plugged with some cloth. Since the bike was outside for awhile, water entered the transmission through the hole in the bushing.

<a title="Transmission Has Water In It :-(" href="https://www.flickr.com/photos/brook-reams/51841786704/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51841786704_a0bd3060fd_c.jpg" alt="Transmission Has Water In It :-(" width="800" height="600" /></a>
Transmission Has Water In It :-(

Here is the documentation of how I do this work along with a short YouTube video summarizing the procedure.
<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 R80ST Remove Transmission</a></li>
</ul>

<strong>VIDEO: <em>1983 R80ST Remove Transmission</em></strong>

I am ready to remove the engine. Before I do that I will remove the top end of the engine to reduce the weight.

<a title="Transmission Removed" href="https://www.flickr.com/photos/brook-reams/51840484117/in/album-72177720296199235/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51840484117_46c7ab02b3_c.jpg" alt="Transmission Removed" width="800" height="600" /></a>
Transmission Removed
 
Nice Work Brooks !

I can't tell you how much I appreciate your articles... and have been using your /5 articles for 4 years now on my project.
thank you
brant
 
Nice Work Brooks !

I can't tell you how much I appreciate your articles... and have been using your /5 articles for 4 years now on my project.
thank you
brant

Thank you Brant. You are the reason I take the time to document my projects. The more airheads flying down the road, the happier the universe will be. :):)

Best.
Brook.
 
1983 R80ST Remove Top End & Cam Followers

In preparation for removing the engine from the frame, I remove the top end (valve covers, heads, cylinders, wrist pin, cylinders) to reduce the weight. Although not part of the engine top end, I also removed and inspected the cam followers as it is convenient to do that now.

<a title="Transmission Removed" href="https://www.flickr.com/photos/brook-reams/51840484117/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51840484117_46c7ab02b3_c.jpg" alt="Ready To Remove Top End" width="800" height="600" /></a>
Ready To Remove Top End

This is not the first time I've done this. The 1983 R100RS motor is built the same as the 1983 R80ST motor, so the procedure I documented for the 1983 R100RS applies here as well. Rather than duplicate that procedure, here is the link to the documentation on the 1983 R100RS which contains all the details you need to complete this work.
<ul class="children">
<li class="page_item page-item-6864"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-bmw-1983-r100rs-remove-engine-top-end/">11 BMW 1983 R100RS Remove Engine Top End</a></li>
</ul>
This document will provide a brief summary of the procedure with pictures of what I found as I did this work on the R80ST engine and I did shoot a short video of doing this work on the R80ST.


<strong>VIDEO: <em>1983 R80ST Remove Engine Top End and Cam Followers</em></strong>

And here is the longer video I made for the 1983 R100RS which contains additional information you may find helpful. However, I didn't show removing the cam followers in this one.

VIDEO: 1983 R100RS Remove Engine Top End

Here is what the bike looks like now.

<a title="Engine Top End Removed" href="https://www.flickr.com/photos/brook-reams/51847090359/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51847090359_5596636316_c.jpg" alt="Engine Top End Removed" width="800" height="600" /></a>
Engine Top End Removed

<a title="Engine Top End Removed" href="https://www.flickr.com/photos/brook-reams/51847090319/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51847090319_59c09941b1_c.jpg" alt="Engine Top End Removed" width="800" height="600" /></a>
Engine Top End Removed

<a title="Engine Top End Removed" href="https://www.flickr.com/photos/brook-reams/51847090294/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51847090294_86e515c3a6_c.jpg" alt="Engine Top End Removed" width="800" height="600" /></a>
Engine Top End Removed
 
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.

<a title="Engine Top End Removed" href="https://www.flickr.com/photos/brook-reams/51847090359/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51847090359_5596636316_c.jpg" alt="Engine Top End Removed" width="800" height="600" /></a>
Engine Top End Removed

This documents how I do this work with a short YouTube video.
<ul class="children">
<li class="page_item page-item-9815"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/11-bmw-1983-r80st-remove-engine-from-frame/">11 BMW 1983 R80ST Remove Engine From Frame</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R80ST Remove The Engine From The Frame</em></strong>

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

<a title="Engine Ready For Rebuilding" href="https://www.flickr.com/photos/brook-reams/51848867096/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51848867096_afe1395b88_c.jpg" alt="Engine Ready For Moving Around The Shop" width="800" height="600" /></a>
Engine Ready For Moving Around The Shop

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

<a title="Frame" href="https://www.flickr.com/photos/brook-reams/51849191549/in/album-72177720296259835/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51849191549_f2d4d7a2be_c.jpg" alt="Frame" width="800" height="600" /></a>
Frame

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

<a title="Bike Disassembled With Parts In Bins" href="https://www.flickr.com/photos/brook-reams/51851211912/in/dateposted-public/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51851211912_28d4d30816_c.jpg" alt="Bike Disassembled With Parts In Bins" width="800" height="600" /></a>
Bike Disassembled With Parts In Bins
 
1983 R80ST Disassembly Down To The Frame

This document shows how I disassemble a 1983 BMW R80ST "project bike" down to the frame.
<ul class="children">
<li class="page_item page-item-9631"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r80st-charity-rebuild-project-index/00-bmw-1983-r80st-disassembly-down-to-the-frame/">00 BMW 1983 R80ST Disassembly Down To The Frame</a></li>
</ul>
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.

<a title="Delivered To Brook's Airhead Garage" href="https://www.flickr.com/photos/brook-reams/51730769380/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51730769380_a6f7af5588_c.jpg" alt="As Delivered To Brook's Airhead Garage" width="800" height="600" /></a>
As Delivered To Brook's Airhead Garage

<a title="Additional Parts" href="https://www.flickr.com/photos/brook-reams/51730132613/in/album-72157720265271480/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51730132613_959db3c2bf_c.jpg" alt="Additional Parts That Had Been Removed" width="800" height="600" /></a>
Additional Parts That Had Been Removed

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

<a title="Disassembled R80ST Parts In Boxes" href="https://www.flickr.com/photos/brook-reams/51851129920/in/album-72177720295825079/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51851129920_439cfda80f_c.jpg" alt="Disassembled 1983 R80ST With Parts In Bins" width="800" height="600" /></a>
Disassembled 1983 R80ST With Parts In Bins
 
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.

<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="Engine Block & Transmission When I Found The Bike" width="800" height="600" /></a>
Engine Block & Transmission When I Found The Bike

<a title="Engine VIN# Covered In Oil" href="https://www.flickr.com/photos/brook-reams/51743749710/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51743749710_e135be294b_c.jpg" alt="Engine Block When I Found The Bike" width="800" height="600" /></a>
Engine Block When I Found The Bike

<a title="Serial Number Block On Left, Bottom Of Engine Block" href="https://www.flickr.com/photos/brook-reams/51733142642/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51733142642_e9accf5a8b_c.jpg" alt="Lower Left Of Engine Block When I Found The Bike" width="800" height="600" /></a>
Lower Left Of Engine Block When I Found The Bike

<a title="Oil Filter Cover" href="https://www.flickr.com/photos/brook-reams/51733142897/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51733142897_0f29cfb822_c.jpg" alt="Lower Left Of Engine Block When I Found The Bike" width="800" height="600" /></a>
Lower Left Of Engine Block When I Found The Bike

<a title="Oil Pan And Bottom Of Transmission" href="https://www.flickr.com/photos/brook-reams/51734612314/in/album-72157720218398514/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51734612314_52659d3e90_c.jpg" alt="Oil Pan And Bottom Of Transmission When I Found The Bike" width="800" height="600" /></a>
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.

<a title="Left Side, Lower Block Still Filthy" href="https://www.flickr.com/photos/brook-reams/51882276018/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51882276018_16a936ce8e_c.jpg" alt="Left Side, Lower Block Still Filthy" width="800" height="600" /></a>
Left Side, Lower Block Still Filthy

<a title="Rear Block Filth" href="https://www.flickr.com/photos/brook-reams/51881228847/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51881228847_dd247db9d2_c.jpg" alt="Shelf At Rear Of The Block Was Filthy With Thick Gunk I Removed With A Paint Scraper" width="800" height="600" /></a>
Shelf At Rear Of The Block Was Filthy With Thick Gunk I Removed With A Paint Scraper

<a title="Right Side, Lower Block Still Filthy" href="https://www.flickr.com/photos/brook-reams/51882275943/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51882275943_4467ff630f_c.jpg" alt="Right Side, Lower Block Still Filthy" width="800" height="600" /></a>
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.

<a title="All Done-Left Side" href="https://www.flickr.com/photos/brook-reams/51882200076/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51882200076_d7485cef7e_c.jpg" alt="All Done-Left Side" width="800" height="600" /></a>
All Done-Left Side

<a title="All Done-Left Side" href="https://www.flickr.com/photos/brook-reams/51881228512/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51881228512_5d16bc7566_c.jpg" alt="All Done-Left Side" width="800" height="600" /></a>
All Done-Left Side

<a title="All Done-Rear" href="https://www.flickr.com/photos/brook-reams/51882275628/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51882275628_a71aa4c1d7_c.jpg" alt="All Done-Rear" width="800" height="600" /></a>
All Done-Rear

<a title="All Done-Right Sise" href="https://www.flickr.com/photos/brook-reams/51881228462/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51881228462_658d86e6c8_c.jpg" alt="All Done-Right Side" width="800" height="600" /></a>
All Done-Right Side

<a title="All Done-Right Side" href="https://www.flickr.com/photos/brook-reams/51881228437/in/album-72177720296685752/" target="_blank" rel="noopener" data-flickr-embed="true" data-header="true"><img src="https://live.staticflickr.com/65535/51881228437_c1331c49db_c.jpg" alt="All Done-Right Side" width="800" height="600" /></a>
All Done-Right Side

I hope this is helpful.
 
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Brook, thanks for the video regarding the engine case "cleaning". How long does the cleaning/refinishing last?
 
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.
 
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