1983 BMW R80ST Install Transmission

After removing the transmission, I disassembled it, had the case and rear cover vapor blasted, rebuilt the shift cam assembly, input, intermediate and output shafts and reassembled the transmission. You can read about that work here.

So, now I’m ready to install it. I also install the clutch throw-out lever assembly, foot shifter assembly, clutch cable and speedometer cable. Here is a link to the documentation about installing the 1983 R80ST transmission and a YouTube video.

VIDEO: 1983 BMW R80ST Install Transmission

Here are the before and after pictures of the transmission.

Transmission Condition As I Found It

Transmission Condition As I Found It

Transmission Condition As I Found It

Transmission Condition As I Found It

Transmission Installed

Transmission Installed

Transmission Installed

Transmission Installed

 

1983 BMW R80ST Install Front Brake

The 1983 R80ST has a single front disk brake. The brake disk is mounted on the right side of the front wheel. This bike did not have the front disk, so I got a new one. I rebuilt the front brake caliper and you can see how I do that here.

Here is the description of how install the front brake and a summary YouTube video of how I do this work.

VIDEO: 1983 BMW R80ST Install Front Brake

1983 BMW R80ST Rebuild Front Brake Caliper

The 1983 R80ST has a single front disk brake on the right side of the front wheel. It uses a Brembo caliper connected to a master cylinder and fluid reservoir built into the right handlebar control unit.  I repainted the caliper using black caliper paint.

Here is what the caliper looked like when I got the bike removed it from the bike.

As Found: Front Brembo Disk Brake Caliper And Missing Brake Rotor

As Found: Front Brembo Disk Brake Caliper And Missing Brake Rotor

Brembo Front Brake Caliper With Crusty Looking Brake Pads

Brembo Front Brake Caliper With Crusty Looking Brake Pads

And this is how it looks after repainting and rebuilding.

Brembo Front Caliper After Rebuilding

Brembo Front Caliper After Rebuilding

Brembo Front Caliper After Rebuilding

Brembo Front Caliper After Rebuilding

Brembo Front Caliper After Rebuilding

Brembo Front Caliper After Rebuilding

This shows how I do the work.

Here is a short video summarizing the procedure. It is a mix of video from the 1983 R100RS and 1983 R80ST.

VIDEO: 1983 BMW R80ST Rebuild Front Brake Caliper

 

1983 BMW 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. You can see how I did this work and a summary YouTube video below.

VIDEO: 1983 BMW R80ST Install Handlebar, Instruments & Dash

1983 BMW R80ST Install Electrical System

I replace the main wiring harness and all the sub-harnesses. I also replace all the electrical components. Since this bike sat for almost 25 years and the components and wiring were not in good shape, replacing it all should provide very good reliability.  You can see how I remove what was left of the original electrical system here.

Here is a link to the documentation and YouTube video summary of how I do this work.

VIDEO: 1983 BMW R80ST Install Electrical System