The 1983 R80ST “project bike” came with a rear fender but no front fender. A friend of mine donated a front fender for this charity rebuild project. It took awhile to get the parts back from the painter. Unlike the fenders on many other airhead models, the R80ST fenders do not have pinstripes. Here are pictures of what I started with and what the newly painted parts look like.
For the rear fender, the stainless steel bolt kit I bought from Motor Works BMW had new rear fender hardware. I got the front fender mounting hardware from MAX BMW, except for the lock nuts which are no longer available. I reused the rear fender lock nuts on the front fender. I got the BMW Rondel and stickers for the rear fender from from Euro MotoElectrics. They resell decals and stickers from Heritage Stickers, who I have used in the past.
|46 61 1 236 898||SAUCER-HEAD SCREW – M5X14; Front Fender||4|
|46 61 1 236 899||RUBBER WASHER; Front Fender||4|
|07 11 9 936 439||WASHER – 5,3-140 HV-ZNS; Front Fender||4|
|46 61 1 236 900||CAP; Front Fender||4|
|46 54 1 239 455||EMBLEM – “BMW”||1|
Here is a summary video of how I install the fenders.
VIDEO: 1983 BMW R80ST Install Fenders
Install Front Fender
Most airhead bikes have a lower fender bracket, but the R80ST does not. It mounts to the front fork brace with four carriage bolts, a rubber grommet next to the outer side of the fender, a flat washer, a lock nut and a black plastic cap over the lock nut.
The shorter end of the fender points to the front and the longer end to the rear.
I find it’s easier to mount the fender with the fork seal rubber boots pulled up the fork legs. Then I can slide the fender over the fork brace and align the fender holes with the holes in the fork brace.
I insert the carriage bolt from the inside of the fork brace, mount the rubber grommet, the flat washer and the lock nut. After I mount all four carriage bolts, I install the black plastic caps on the lock nuts.
Here is the newly painted and mounted front fender.
Install Rear Fender
The rear fender mounts on a set of backets on the rear sub-frame. There are a pair of brackets towards the front and a pair towards the rear and the holes in the fender align with them. There is also a set pins on the lower frame that the holes in the bottom of the fender rest on.
The rear fender mounting hardware includes a plate that fits on the inside of the fender, a bolt and flat washer that go against the plate, a rubber grommet, flat washer and lock nut that go on the outside of the fender. I like to use two short pieces of vacuum hose on the lower pins so the lower holes in the fender don’t get cracked from vibration.
I install the fender on the lower pins and then install the front and rear hardware on the sub-frame brackets. The rubber grommet goes between the top side of the fender and the underside of the bracket. The flat washer, wave washer and nut go on the top side of the bracket.
Here is the rear fender mounted on the rear sub-frame.
Mount Rear Tail Light
The rear tail light mounts on the back of the rear fender with two bolts, flat washers, wave washers and nuts. I remove the lens and pull the reflector out of the way so I can mount the tail light housing to the rear fender.
Then I insert the reflector, and attach the lens with the two screws. The tail light wiring harness routes along the outside of the fender instead of going through the fender and routing along the inside of the rear fender.
Install BMW Roundel And Stickers
Before I install the rondel and stickers, I use an alcohol pad and clean the fender where they will attach so there is no oil or dirt. A BMW rondel goes on the rear fender and some stickers including the paint code sticker go on the spine of the rear fender. I peal the backing off, carefully locate the rondel so it is centered in the hole and then gently press it down.
Next I install the paint sticker, electronic ignition warning sticker and the tire information sticker on the spine of the rear fender.
Install License Plate Bracket
The license plate bracket has three holes. The bolt goes in from the outside and the flat washer goes against the inside of the fender with the lock nut. I mount the side reflectors on the tabs of the license plate bracket after I mount the bracket.
Here is what all done looks like.