32 BMW 1983 R80ST Install Handlebars, Instruments, Dash

After I installed the electrical system, I install the handlebars, the instruments (speedometer and tachometer), the dash and the handlebar controls and multi-function switches.

Parts

All the parts were generously supplied by Euro MotoElectrics for free in support of my goal to auction this bike and provide all proceeds to the Motorcycle Relief Project.

Part #                  Description                                                                   Qty
32 72 1 237 811  RUBBER GRIP, LEFT, Clutch Side 1
32 71 2 307 401  HANDLEBAR, RAISED, CHROME 1
32 71 1 242 932  CAP, Instrument Dash 1
32 72 1 454 129  THROTTLE GRIP (from 09/80), Throttle Side w/ Tube 1
32 72 1 241 862  HANDLE UNIT LEFT 1
32 72 2 302 367  HANDLE UNIT, RIGHT – D=12MM (from 09/81) 1
61 31 1 244 420  COMBINATION SWITCH LEFT 1
61 31 1 244 417  COMBINATION SWITCH RIGHT 1
61 32 1 243 656  PLATE, Ignition Switch 1
31 42 1 242 397  RING, Ignition Switch 1

NOTE:
The handlebar I got from Euro MotoElectrics has about one-half the rise (4 inches) of the stock handlebars (8 inches), so they are a bit flatter.

I have the original ignition switch which is working just fine. The combination switches (aka multi-function switches) were part of the complete electrical system replacement I document here.

Video

VIDEO: 1983 BMW R80ST Install Handlebar, Instruments & Dash

Install Handlebar

The dash covers the handlebar risers, so I mount the handlebar first. I put the upper and lower risers on the handlebar and then insert the studs of the risers into the holes on the top brace. The handlebar will sit in the risers without falling out. Then I install the nuts and wave washers on the bottom of the top plate to secure the handlebars in the risers. I leave the nuts a bit loose so I can rotate the handlebars while I install the instruments, dash and handlebar controls.

Handlebar Riser Hardware Detail: I Painted The Risers And Cleaned Up The Hardware

Handlebar Riser Hardware Detail: I Painted The Risers And Replaced The Hardware

Repainted Handlebar Risers With New Nuts & Washers (Left)

Repainted Handlebar Risers With New Nuts & Washers (Left)

Handlebars Resting In Handlebar Risers

Handlebars Resting In Handlebar Risers

Nuts & Wave Washers Secure Handlebar Risers To Top Plate

Nuts & Wave Washers Secure Handlebar Risers To Top Plate

NOTE:
I installed a Toaster Tan top brace instead of the stock BMW top plate. Unlike the two R100RS bikes I installed a Toaster Tan top brace on, the R80ST does not have an instrument bracket, so the handlebar risers do not need to be modified with long studs. The stock handlebar risers mount to the Toaster Tan top brace just the same as they mount to the BMW top plate.

Mount Ignition Switch In Headlight Bracket

The R80ST ignition switch mounts to the dash using a thick spacer and a nut. An indicator plate fits over the ignition switch on the top of the dash and is secured with a black ring nut.

R80ST Ignition Switch Mounting Parts

R80ST Ignition Switch Mounting Parts

Ignition Switch Bracket Mounting Hardware

Ignition Switch Bracket Mounting Hardware

Thick Ring Goes Under Mounting Bracket, Nut Goes On Top Of Bracket

Thick Ring Goes Under Mounting Bracket, Nut Goes On Top Of Bracket

I mount the ignition before mounting the instruments. You can’t fit the switch into the hole in the headlight bracket if the instruments are mounted. The hole has a ridge that fits into one of the two grooves in the side of the ignition switch so it is positioned correctly.

Tab On Inside Of Hole Fits In Slot On Side Of Ignition Switch To Orient Ignition Switch

Tab On Inside Of Hole Fits In Slot On Side Of Ignition Switch To Orient Ignition Switch

NOTE:
The switch is in the wrong orientation in the above photo. Read the following paragraph.

Since there are two grooves, the ignition switch can be mounted in two positions 180 degrees apart. But, the markings on the plate that fits over the top of the switch is designed so the pointer on the fold over key points at the correct indication on the plate: OFF, PARK, ON. To get the ignition switch in the correct orientation, the teeth of the key should point down when the ignition switch is mounted correctly. Since I don’t have the fold over key for the R80ST, I used the one on my 1983 R100RS to ensure I mounted the ignition switch in the correct orientation. I had the switch in the OFF position, so that means the pointer should be at about 10:00 when the ignition switch is mounted in the bracket.

Checking Ignition Switch Is Correctly Oriented In OFF Position: Pointer On Fold Over Key At 10:00 Position

Checking Ignition Switch Is Correctly Oriented In OFF Position: Pointer On Fold Over Key At 10:00 Position

The wires to the back of the switch extend through a second hole in the bracket. I install the wires before mounting the switch. I document how to get the wires on the correct ignition switch terminals here:

I have to tip the headlight down in order to get enough room to install the ignition switch into the hole in the top of the headlight bracket.

Ignition Switch Installed In Hole In Headlight Bracket

Ignition Switch Installed In Hole In Headlight Bracket

Ignition Switch Installed In Hole In Headlight Bracket-Ring Below Bracket, Nut On Top Of Bracket

Ignition Switch Installed In Hole In Headlight Bracket-Ring Below Bracket, Nut On Top Of Bracket

Ignition Switch Wires Protrude Thru Bottom Hole In Headlight Bracket

Ignition Switch Wires Protrude Thru Bottom Hole In Headlight Bracket

Install Instruments: Speedometer & Tachometer

The speedometer and tachometer have a bracket welded on the side that has two M5 studs that fit into holes in the top of the headlight bracket. Each instrument is secured with two nuts and wave washers.

Instrument Bracket With M5 Studs

Instrument Bracket With M5 Studs

Speedometer Mounted To Headlight Bracket With 2 M5 Nuts And Wave Washers

Speedometer Mounted To Headlight Bracket With 2 M5 Nuts And Wave Washers

I install the turn indicator wires to the bulb sockets on the back of the dash. The BLUE-Black wire goes on the right and the BLUERed wire goes on the left, as you are sitting on the bike. The BROWN ground wires go on the terminals at the side of the bulb sockets and the BLUE wires go on the terminals that go to the center of the bulb sockets.

BLUE-Red On Left Terminal, BROWN Ground On Right Terminal

BLUERed On Left Terminal, BROWN Ground On Right Terminal Of Left Turn Signal Indicator

Dash Turn Signal Indicator Wires Installed

Dash Turn Signal Indicator Wires Installed

The dash bottom cover is secured with two Tinnerman clips on the sides of the dash and screws.

Bottom Dash Cover Tinnerman Clip

Bottom Dash Cover Tinnerman Clip

Bottom Dash Cover Screw And Washer

Bottom Dash Cover Screw And Washer

Dash Bottom Cover Installed

Dash Bottom Cover Installed

Install Ignition Switch Plate

The ignition switch plate has two tabs that fit into the two slots on the side of the ignition switch. It is secured with the black ring with two holes in it. I use two nails and a screwdriver to tighten the black ring.

Using Two Nails & Screwdriver To Tighten Ring Nut To Secure Ignition Plate

Using Two Nails & Screwdriver To Tighten Ring Nut To Secure Ignition Plate

Ignition Switch Plate And Ring Nut Installed

Ignition Switch Plate And Ring Nut Installed

I verify the switch is mounted in the correct orientation using the 1983 R100RS fold over key.

Pointer Of Fold Over Key Points To Correct Label When Ignition Switch Is In OFF Position

Pointer Of Fold Over Key Points To Correct Label When Ignition Switch Is In OFF Position

Note that the flat key will point to ON when the ignition is off since it does not have the pointer.

Flat Key In OFF Position Points to ON

Flat Key In OFF Position Points to ON

Install Handlebar Controls

I bought new handlebar controls so I don’t have to install the levers or the front disk brake master cylinder and fluid reservoir.

Handlebar Controls: LEFT-Clutch & Choke; RIGHT-Throttle & Front Disk Brake

Handlebar Controls: LEFT-Clutch & Choke; RIGHT-Throttle & Front Disk Brake

The left handlebar control includes the clutch and choke while the right handlebar control includes the throttle and front disk brake master cylinder and brake fluid reservoir. I’ll install the clutch and throttle cables when I install the transmission and carburetors. I’ll install the disk brake line when I install the front disk brake system. For now, I’m only going to install the handlebar multi-function control switches, the clutch and the front brake light switches.

Install Right Handlebar Control

The right handlebar control includes the throttle tube. It has teeth cut into it that mate with the teeth of the throttle cam the fits inside the housing on top of the control. I’ll install the original throttle cam cam and throttle cable later when I install the carburetors. The throttle tube has a groove that the foot on the bottom of the throttle housing cover fits into to secure the throttle tube in the handlebar control. I mount the throttle tube and secure the throttle housing cover with the bolt.

Groove In Throttle Tube That The Foot On The Throttle Cam Cover Plate Engages

Groove In Throttle Tube That The Foot On The Throttle Cam Cover Plate Engages

Throttle Cam Cover With Foot That Secures The Throttle Tube

Throttle Cam Cover With Foot That Secures The Throttle Tube

Throttle Cam Cover Bolt

Throttle Cam Cover Bolt

The front brake light switch screws into a hole in the handlebar control. It comes with a washer, but on this handlebar control, I don’t need the washer.

NOTE:
I initially installed the washer, but the rear brake light would not go out because the plunger on the front switch was too far from the handlebar lever to compress it. When I removed the washer, the front brake light switch worked correctly.

Hole In Right Handlebar Casting Where Front Brake Light Switch Screws In

Hole In Right Handlebar Casting Where Front Brake Light Switch Screws In

Front Brake Light Switch With Washer-BUT This Handlebar Casting Does NOT Use The Washer

Front Brake Light Switch With Washer-BUT This Handlebar Casting Does NOT Use The Washer

I slide the handlebar control onto the left arm of the handlebar. Then I screw in the front brake light switch and attach the two wires on the front brake switch sub-harness, GREENRed and GREEN-Black, onto the spade terminals of the switch. Then I slide the rubber boot over the terminals and onto the end of the switch to keep water out of the switch.

Front Brake Switch Sub-Harness Connected

Front Brake Switch Sub-Harness Connected

Rubber Boot On Front Brake Switch

Rubber Boot On Front Brake Switch

The front brake switch sub-harness routes down the handlebar and in front of the steering stem, then down the side of the steering stem, and back along the spine tube and over to the plug on the left side of the main wiring harness that has the GREENRed and GREEN-Black wires.

Front Brake Light Sub-Harness Routing

Front Brake Light Sub-Harness Routing

Front Brake Light Sub-Harness Routing

Front Brake Light Sub-Harness Routing

Front Brake Switch Sub-Harness Plugs Into Main Wiring Harness Plug

Front Brake Switch Sub-Harness Plugs Into Main Wiring Harness Plug

Install Left Handlebar Control

The left handlebar control has a slot with two holes for the clutch switch. My clutch switch was a bit wide, so I sanded the sides so it would fit all the way down into the slot. The switch is secured with an M3 bolt and washer into the bottom hole which is tapped. I install the clutch switch before I install the handlebar control on the handlebar as it’s easier to get the screw mounted in the hole on the work bench.

Large Hole For Clutch Switch Plunger Above Small Hole For Mounting Bolt

Large Hole For Clutch Switch Plunger Above Small Hole For Mounting Bolt

Clutch Switch Detail-I Had To Sand Down The Side So It Would Fit Flush In The Slot In The Handlebar Control

Clutch Switch Detail-I Had To Sand Down The Side So It Would Fit Flush In The Slot In The Handlebar Control

Clutch Switch Fits In Slot In Left Handlebar Control

Clutch Switch Fits In Slot In Left Handlebar Control

M3 Bolt Secures Clutch Switch In Left Handlebar Control

M3 Bolt Secures Clutch Switch In Left Handlebar Control

M3 Bolt Secures Clutch Switch In Slot

M3 Bolt Secures Clutch Switch In Slot

I install the handlebar control onto the left arm of the handlebar. I route the clutch switch sub-harness similarly to the way I routed the right side front brake switch sub-harness. I connect the sub-harness to the plug on the right side of the main wiring harness with the BROWNYellow and BROWN wires.

Clutch Switch Sub-Harness Plugs Into Socket On Main Wiring Harness

Clutch Switch Sub-Harness Plugs Into Socket On Main Wiring Harness

Mount Mirrors and Left Handlebar Grip

The mirrors mount in holes in the handlebar controls with a lock nut and washer on the bottom. I install the left handlebar grip using some liquid tire mounting lubricant that I spay inside the tube so it is easy to slide onto the handlebar. The tire mounting lubricant will dry and the grip will stay tight on the handlebar. You can use water with a bit of dish detergent to lubricate the inside of the handlebar grip.

Left Mirror And Left Handlebar Grip Mounted

Left Mirror And Left Handlebar Grip Mounted

Install Multi-Function Switches

The left and right multi-function switches attach to the handlebar controls with an Allen bolt at the bottom of the switches.

Hole In Handlebar Control For Multi-Function Switch Allen Bolt

Hole In Handlebar Control For Multi-Function Switch Allen Bolt

Allen Bolt At Bottom Secures Multi-Function Switch To Handlebar Casting

Allen Bolt At Bottom Secures Multi-Function Switch To Handlebar Casting

Left Multi-Function Switch Installed

Left Multi-Function Switch Installed

Right Multi-Function Switch Installed

Right Multi-Function Switch Installed

Testing Handlebar Multi-Function Switches & Dash Lights

As I did when I installed the electrical system, I tested the multi-function switches and dash lights to be sure everything is still working. Here is how I did the test.

Everything worked. 🙂  Here is what all done looks like.

Handlebars, Instruments & Dash Installed

Handlebars, Instruments & Dash Installed

Revisions

2023-01-02 Updated ignition switch install to show correct hardware BMW used.
2023-01-03 Update video to show correct ignition switch hardware install.

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