At last, I get to start putting this motorcycle back together. Every time I install an engine in the frame it’s a milestone. Instead of taking things apart, I am starting down the road to getting it all back together again :-).

Here is a link to the documentation and the video I shot.

• 11 BMW 1983 R80ST Install Engine In The Frame

VIDEO: 1983 BMW R80ST Install Engine In Frame

I had the frame powder coated.

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.

The top is off the engine so it’s lighter and easier to install in the frame.

This is the hardware used to mount the engine in the frame.

It’s mounted on my portable motorcycle lift ready to install the top end.

 

The R80ST has spoked wheels front and rear. In order to refinish the wheels using vapor blasting, I remove the spokes. This let me assess the condition of the spokes and spoke nipples so I can decide if I can keep most of them, or they need to be replaced.

On the rear wheel only 17 out of 40 spokes weren’t bent or rusted and only 8 spoke nipples were not damaged. On the front wheel every spoke was bent. So I replace all the spokes with stainless steel spokes and install new plated brass nipples.

This documents shows how I do this work.

• 36 BMW 1983 R80ST Refinish, Lace & True Wheels

And this video shows the techniques I use in more detail.

VIDEO: 1983 BMW R80ST Lace The Spokes And True The Wheels

Here is what I started with.

And here is what the wheels look like after refinishing them and lacing and truing the wheels with new stainless steel spokes.

Before I install new stainless steel spokes and chrome plated brass spoke nipples, I replace the front wheel bearings. The rear wheel does not have wheel bearings. Instead it is mounted directly to the rear drive. Since the rear wheel does not have an axle, there is no need for wheel bearings.

Here is a link to the documentation on how I do this work and a short YouTube video that summarizes the procedure.

• 36 BMW 1983 R80ST Replace Wheel Bearings & Set Bearing Pre-Load

VIDEO: 1983 BMW R80ST Replace Wheel Bearings & Set Pre-Load

I had the cylinders vapor blasted. In preparation, I removed the push rod tubes. After they were vapor blasted I install new stainless steel pushrod tubes I got from Euro MotoElectrics, who graciously has agreed to provide the parts for this charity rebuild project for free. I will auction this bike and proceeds will go to the Motorcycle Relief Project.

I have done this work before on my 1983 R100RS rebuild and will reference material from the documentation of that build as appropriate.

• 11 BMW 1983 R100RS Remove Push Rod Tubes & Head Studs
• 11 BMW 1983 R100RS Install Push Rod Tubes & Head Studs

Here is what I started with before vapor blasting the cylinders and replacing the push rod tubes.

Here is a link to the documentation and a short YouTube video summarizing the procedure.

• 11 BMW 1983 R80ST Replace Push Rod Tubes

VIDEO: 1983 BMW R80ST Replace Push Rod Tubes

This is the final result.

I removed the swing arm bearings before I had the swing arm powder coated. The swing arm bearings are the same sealed bearings used on the 1983 R100RS that I previously rebuilt, so the procedure for replacing them on the R80ST is the same. In this document I link to the previous documentation for the 1983 R100RS as appropriate.

• 33 BMW 1983 R80ST Replace Swing Arm Bearings

Here is a short video summarizing the work.

VIDEO: 1983 BMW R80ST Replace Swing Arm Bearings

Earlier versions of the airhead swing arm used traditional bearings with a separate inner and outer race. I show how to replace that style swing arm bearing here.

• 33 BMW 1973 R75/5 Remove & Install New Swing Arm Bearings