I completed the first engine start and a 10 mile break-in ride. You can see the details here.
VIDEO: 1983 BMW R80ST First Engine Start
1983 BMW R80ST First Engine Start
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1983 BMW R80ST Assemble & Install Gas Tank
This “project bike” came with it’s original gas tank. There was a small dent in the tank near the front and scraps and gashes in the paint. The inside red tank lining was in good condition. I had it repaired and repainted. I refurbished the gas cap, put on new BMW roundels, replaced the rear bracket that secures the tank to the spine tube and installed new fuel lines.
Here are some before and after pictures of the gas tank.
Original Gas Tank Condition
Original Gas Tank Condition
Original Gas Tank Condition
Dent In Front Of Original Gas Tank
R80ST Painted Gas Tank
R80ST Painted Gas Tank
R80ST Inside Gas Tank
Here it is installed on the bike.
Gas Tank Installed
Gas Tank Installed
This is a link to the documentation of how I did this work and a summary video of the procedure.
VIDEO: 1983 BMW R80ST Assemble & Install Gas Tank
1983 BMW R80ST Install Fenders
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.
Donated Front Fender
Donated Front Fender
R80ST Painted Front Fender
Original Rear Fender
Original Rear Fender
R80ST Painted Rear Fender
Here is a link to the documentation of how I did the work, and a summary video.
VIDEO: 1983 BMW R80ST Install Fenders
1983 BMW R80ST Install Exhaust System
This R80ST came with no right exhaust header or collector box. I decided to replace the entire exhaust system as the rear muffler and left header had a fair amount of rust.
Left Header Pipe Mounted Wrong And Rear Muffler
Corrosion On Muffler
Right Side Missing Exhaust Header
Here is the new exhaust system installed. I’ll install the muffler heat shield when I get the side panels back from the painter.
All Done
All Done
All Done
This is a link to the documentation and a short YouTube video summary of how I do this work.
VIDEO: 1983 BMW R80ST Install Exhaust System
Airhead Special Tools List
I assembled a document showing the special tools I have acquired to work on my rebuild/restore projects. So I thought I would let you know about it.
It is organized according to the parts numbering system main categories so it is easier to find the tools you may need based on the work you are thinking of doing. You can contact your ABC air marshal to see if someone in your state has a tool they would loan you so you can use a tool without having to buy it.
That said, this is only a list of tools I have needed, not necessarily all the tools you may need for all work on our airhead bikes. I hope this is helpful.