1983 BMW R80ST Install Flywheel

I’ve removed the airbox, transmission and clutch to gain access to the flywheel. You can see how I did that work here.

I also show how to remove the flywheel here.

I’ve published documents on removing and installing the flywheel on other projects. You can see those documents here.

Since the 1983 R80ST engine is similar in many ways to the 1983 R100RS, I will link to the 1983 R100RS documents as appropriate in this document.

Here is a short YouTube video showing how I do this work.

VIDEO: 1983 BMW R80ST Install Flywheel

Here is how things look now.

Flywheel Installed

Flywheel Installed

 

1983 BMW R80ST Disassembly Down To The Frame

This document shows how I disassemble a 1983 BMW R80ST “project bike” down to the frame.

It has links to other documents that describe how to remove various assemblies such as the electrical system, brakes, drive train, engine etc. Although not included in this document, there will be other documents that cover details about the disassembly and rebuilding of some of the components removed in this document; e.g., the master cylinder, disk calipers, wheel bearings, etc.

I got the bike in November 2021 as a project bike. Consequently, a number of parts were not installed on the bike so I won’t be showing how to remove them. Nonetheless, I list the removal of parts in the order that I would have removed them so you can use this document as a guide for removing all the parts from the bike to strip it down to the frame.

As Delivered To Brook's Airhead Garage

As Delivered To Brook’s Airhead Garage

Additional Parts That Had Been Removed

Additional Parts That Had Been Removed

After I finished disassembling it and storing parts in bins, this is what it looks like.

Disassembled 1983 R80ST With Parts In Bins

Disassembled 1983 R80ST With Parts In Bins

 

Adding Cloth Storage Bags To The RT Fairing

I converted this 1983 R100RS into an RT by adding the RT fairing. The RT fairing comes with hard plastic side pockets, but they are much too close to the gas tank for my taste.

R100RT Fairing Interior View Showing How Close Plastic Pockets Are To Gas Tank

R100RT Fairing Interior View Showing How Close Plastic Pockets Are To Gas Tank

So, I decided to install a set of cloth bags that provide storage and don’t get very close to the gas tank. I used Fairing Pockets from “Kathy’s Journey Designs”, that are designed to work with the RS fairing.

Kathy's Journey Design Fairing Pockets Come In Different Colors; Mine Are Black

Kathy’s Journey Design Fairing Pockets Come In Different Colors; Mine Are Black

You can read all about how I did this project here.

I mount the RS fairing pockets on the RT fairing using the existing bushings that the plastic fairing compartments mounts to. There is enough room between that part of the RT fairing and the gas tank that the bags won’t touch the gas tank when they are mounted.

Side Of Fairing Showing Bushings For M6 Bolts Used To Mount Plastic Fairing Pocket

Side Of Fairing Showing Bushings For M6 Bolts Used To Mount Stock Plastic Fairing Compartments: Note Rear Top Bushing Is Shorter Than The Others

I mount the bags using three M6 bolts with a flat and wave washer to the side of the fairing.

Back Of Bag With Three Grommets Installed

Back Of Bag With Three Grommets Installed

Bag Mounting Hardware: M6-10 Bolt, Flat and Wave Washers

Bag Mounting Hardware: M6-10 Bolt, Flat and Wave Washers

M6x10 Bolts Installed Through Grommets In Bag

M6x10 Bolts Installed Through Grommets In Bag

Bag Mounted On Inside of Fairing Leaving Clearance Next To Gas Tank

Bag Mounted On Inside of Fairing Leaving Clearance Next To Gas Tank

1983 BMW R100RS Replace Wheel Bearings and Set Bearing Preload

This bike has 83,000+ miles on it and the wheel bearings are of unknown condition. So I replace them and set the wheel bearing preload. I also had the wheels powder coated after I removed the old bearings, so I had to also remove the disk brake rotors. I show how I remove, refinish and install the disk brake rotors in this document.

Of course, you can remove the wheel bearings without removing the disk brake rotors.

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

VIDEO: 1983 BMW R100RS Replace Wheel Bearings and Set Bearing Preload

And some pictures highlighting the work.

Wheel Bearing Parts, Left-to-Right: Dust/Grease Seals (Rear Right at Bottom); Top Hats; Wheel Bearings

Wheel Bearing Parts Left-to-Right (Right Rear at Bottom): Grease Seals ; Top Hats; Wheel Bearings

Cycle Works Swing Arm Bearing Puller Kit-Works On Wheel Bearings As Well

Cycle Works Swing Arm Bearing Puller Kit-Works On Wheel Bearings As Well

Rear Wheel Bearing Outer Race Removed

Rear Wheel Bearing Outer Race Removed

Rear Wheel Center Pipe With Plastic Sleeves On Each End

Rear Wheel Center Pipe With Plastic Sleeves On Each End

AFTER: Powder Coated Wheels in White

Powder Coated Wheels in White

Driving Outer Race To Proper Depth with Cycle Works Aluminum Rectangle From Swing Arm Bearing Race Tool

Driving Outer Race To Proper Depth with Cycle Works Aluminum Rectangle From Swing Arm Bearing Race Tool

String Evenly Wrapped Around Sleeve

String Evenly Wrapped Around Sleeve

Walking With Spring Scale To Measure Preload Force

Walking With Spring Scale To Measure Preload Force

Front Wheel Preload-Four 0.05 mm Shims and Sanded Wedding Band

Front Wheel Preload-Four 0.05 mm Shims and Sanded Wedding Band

Grease Seal and Top Hat Installed

Grease Seal and Top Hat Installed

Finished Wheels

Finished Wheels