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.

• 23 BMW 1983 R80ST Remove Transmission
• 23 BMW 1983 R80ST Disassemble, Rebuild, Assemble Transmission

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.

• 23 BMW 1983 R80ST Install Transmission

VIDEO: 1983 BMW R80ST Install Transmission

Here are the before and after pictures of the transmission.

 

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.

• 34 BMW 1983 R80ST Rebuild Front Brake Caliper

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

• 34 BMW 1983 R80ST Install Front Brake

VIDEO: 1983 BMW R80ST Install Front Brake

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.

And this is how it looks after repainting and rebuilding.

This shows how I do the work.

• 34 BMW 1983 R80ST Rebuild Front Brake Caliper

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

 

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.

• 32 BMW 1983 R80ST Install Handlebars, Instruments, Dash

VIDEO: 1983 BMW R80ST Install Handlebar, Instruments & Dash

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.

• 61 BMW 1983 R80ST Remove Electrical System

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

• 61 BMW 1983 R80ST Install Electrical System

VIDEO: 1983 BMW R80ST Install Electrical System