11 BMW 1983 R80ST Install Engine In The Frame

The frame is powder coated and I have the engine back together with the exception of the top end which lightens the engine making it easier to install it in the frame. I can install the top end easily with the engine in the frame.

When I get the engine in the frame it’s a milestone as from now on parts are going together to create the motorcycle instead of coming off. 🙂

Parts

I replaced the engine studs, washers, and nuts with stainless steel ones I got in the R80ST stainless steel hardware kit I bought from Motoworks BMW.

Engine Mounting Hardware

Engine Mounting Hardware

Video

This video shows how I install the engine in the frame.

VIDEO: 1983 BMW R80ST Install Engine In Frame

Engine Mounting Hardware

The front engine stud is longer than the rear on the R80ST since the engine guards mount on the front engine studs. The front stud is 315 mm and the rear is 298 mm.

There are  bushings that fit between the engine block and the frame. The rear ones are the same size (6 mm thick). The right front is the same size as the rear, but the left front is thicker (9 mm thick). The studs are secured with nuts, wave washers and flat washers.

Left Side Of Front Engine Stud Has Thicker Bushing

Left Side Of Front Engine Stud Has Thicker Bushing

Protecting Powder Coated Frame

I had the frame powder coated.

Powder Coated Frame

Powder Coated Frame

NOTE:
Check the inside of the holes in the frame that the engine studs go through for any power coat. If there is some, sand it off as the clearance is pretty tight between the engine stud bushings and the 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.

Foam Packing Sheet I Use To Protect The Frame

Foam Packing Sheet I Use To Protect The Frame

Frame Protected With Foam Sheets

Frame Protected With Foam Sheets

Putting The Engine Inside The Frame

The engine is front heavy so I put a 2×4 under the timing cover. I also put a 2×4 under the front of the frame to keep it level.

Engine Supported With 2x4

Engine Supported With 2×4

Frame Supported In Front With 2x4

Frame Supported In Front With 2×4

I bend my knees to pick up the engine so I won’t hurt my back. It likely weights 60-70 pounds. I tilt the top of the engine toward me to slide it under the spine tube and then tilt it back and set it down.

Engine Inside Frame

Engine Inside Frame

I slide the frame backward so the rear hole in the engine block is close to the rear hole in the frame.

Rear Engine Stud Hole In Frame

Rear Engine Stud Hole In Frame

Rear Engine Stud Goes Through Engine Block

Rear Engine Stud Goes Through Engine Block

There is a tube the slides between the two bushings cast into the engine block that the rear engine stud slides through.

Metal Tube Fits Between Rear Engine Block Bushings

Metal Tube Fits Between Rear Engine Block Bushings

I found it was easier to tip the frame and engine forward so I can maneuver the frame until the rear engine stud hole is close to the hole in the engine block. I slide the rear engine stud (the shorter one) through the frame and catch the rear spacer on it and then tilt the frame to align the holes and slide the rear engine stud into the hole in the engine block. I use a plastic hammer to tap it through the hole until it’s just protruding out the other side of the engine block. I push it back so it’s flush with the block, insert the other rear bushing and tap it through the bushing and the hole in the frame.

Rear Bushing Goes Between Engine Block And Frame

Rear Bushing Goes Between Engine Block And Frame

Rear Bushing Goes Between Engine Block And Frame

Rear Bushing Goes Between Engine Block And Frame

Rear Busing Installed On Rear Engine Stud

Rear Busing Installed On Rear Engine Stud

Tapping The Rear Stud Through

Tapping The Rear Stud Through

I repeat this procedure for the front engine stud making sure I put the thicker bushing on the left side and the thin one on the right side.

NOTE:
Left and right are traditionally from the perspective of sitting on the bike. So they are reversed in the photos below.

Thicker Bushing Goes On Left Side Of Front Engine Stud

Thicker Bushing Goes On Left Side Of Front Engine Stud

Thinner Bushing Goes On Right Side Of Front Engine Stud

Thinner Bushing Goes On Right Side Of Front Engine Stud

I pick up the frame by the spine tube and put the frame and engine on my portable motorcycle lift on top of a piece of plywood that sits under the oil pan. This distributes the weight across the entire oil pan it doesn’t get damaged.

Harbor Freight Motorcycle Stand with Plywood To Protect Oil Pan

Harbor Freight Portable Motorcycle Lift with Plywood To Protect Oil Pan

I secure the frame with tie down straps and use pieces of the foam packing material under the straps to protect the powder coat. I use the 2×4 under the timing cover to support the front of the engine to stabilize it.

Frame & Engine Mounted On Portable Motorcycle Lift

Frame & Engine Mounted On Portable Motorcycle Lift

I am going to leave the engine stud nuts loose for now as the engine guards mount on the front studs.

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