'83 BMW R 80 ST
The ST as it was when the owner contacted Hugo to see if anyone he knew was interested.
It seems he likes stickers
lots of things put on incorrectly, but still very much the bike I want
The weather outside my house is looking up for the ST trip...
Waiting for the train
Mt. Fuji in the background? Not realy sure.
Tea fields at bullet train speed
My bullet train
Chiyoda subway line
Hugo on his new bike
Hugo, the ST and Vince
Hugo's left head in place
And the right
It runs!! After finding the tie-wrap in the right carb....
Hugo setting the carb ballance
List of things borrowed from Hugo-- seems half the bike..
On Tome expressway to Nagyo
... And twenty minutes later
Katsu curry lunch
A quick stop at my favorite sakeya
In front of the Shinto shrine next to my house
The ST's new home for a bit
ST starting to come back togheher
alignment of the fuel valve -- should it follow the tank or be parallel to the bike?
Mounting points on the frame for the rear fender
.....and on the rear fender
the rear fender mounting hardware - the one on the left seems to be missing two large washers, but after seeing a stock ST I found that the extra washers go on the rear mount.
trying to ID the clip holding the wireloom for the rear light
this is the correct BMW stanchion number for a ST
Is this what the innards of a '83ST fork should be? Turns out to be the innards of a GS.
newly painted parts
something seems off.... or backasswards.
The PO was here!
My new caliper thanks to a fellow Airhead's kindness
Caliper in place
next the engine
Ok, I really need to get the engine in place
New Speigler braided brake line sourced via the Rubber Chicken Racing Gargage.
the Cycle works puller doing its stuff
you can easily see the wear on the left gear
My high tec oven..
driving the heated gear into place after cleaning up the gear edges as advised by Tom Cutter
driving on the bearing
took forever to tape the tops of the fins
a new clutch and other bits
board sourced via Rick at Motorrad Electric
the right signal wire routed on the outside
a bit blurry, but this is what it looks like now
a Siebenrock GS sidestand that was cut to fit a ST by Siebenrock
not so hard when you have some leverage
easy as pie
Lots of particles everywhere
Yet another piece of the puzzle missing..
seems the roller is needed
is this soon to shatter?
Using my new bearing puller and new press not at intended..
Seems to be excessive wear to me
Here you can see how it has groved
Is this amount of play excessive?
This thicker thrust washer on the output shaft - the chamfer was arranged up facing the bearing should it face the gear instead? -- Have learned that the chamfer should face the shoulder.
As far left as it will go
As far right as it will go
New 5% taller fifth gear on the left and the old fifth on the right
new input shaft redesigned in '85
Set up for measuring -- in the end I took the measurements w/out the gasket in place
some new and old tools
My improvised seal driver
all done! Still wondering about the case finish and the S. steel fill plug
all the parts that came out of the gearbox (and were replaced)
Transmission in place
adding holes for the headlight mounting brackets
The Toaster Tan brace with holes added
Mounting bracket in place
Ignition wiring - trying to learn what the black striped green wires do -- Have found a schematic that labels it as, "voltmeter connector"
Cases for the ST
Eastern Beaver H4 headlight relay kit installed
The ST heads at Mr. Kondo's shop - photo by Hugo who went to visit them.. or something like that.
New exhaust valve seats installed by Mr. Kondo at Kondo Engineering in Tokyo -- before being cut.
Almost have a path to the garage..
Have got my ST heads back form Kondo Engineering in Tokyo. Now to install the new pushrod tubes, polish the combustion chambers and really clean everything.
Just don't tell my father I'm not drinking American whiskey
That dark shape on the top right of the snow bridge is a monkey - several more were in the trees to the left.
left side control unit after cleaning and painting
I guess the bar end mirrors are not going to be used.
Ready to be cleaned
Installed the pushrod tubes, rocker arm bases, valve cover center nut stud and exhaust port finned nuts. Ready to install on the ST! Just need to paint the rocker arm covers...
Heads, slugs, jugs and pipes in place!
Hmmm... have I got the wrong finned nut? I've never had a R80 before.
almost there! Just need my wheels and rear diff.
After taking this thing apart I just have to say I'm really impressed that it ran all the way here from Tokyo without a problem. The layer of carbon on the inside is from when the PO ran it with the intake valve lash closed up - the carbon was everywhere.
putting the left carb back together with new and correct jetting
what a difference two days can make..
Trying to understand where this O-ring could go.. not here I suppose. A kind Airhead has told me that it was ment to fit a specially designed slide for the G/S model to prevent the slide from rattling. Anybody want the O-rings?
Starting to look like a BMW
the wheels are done! New S.S.spokes from Seibenrock - rims polished and hubs blasted with three types of medium.
Moto-Bins SS bolts are much too long.
Using a spring scale to check the wheel bearing preload - needed to add a 0.004" spacer. Waxed dental floss works perfectly to spin the axle (and minty fresh!).
It is starting to take shape - now only waiting for the rear diff brake axle shaft to be repaired.
here is the order of spacers for the front hub
Internal spacing in a hub for ST
"Top hat" orientation
BMW tool roll for the ST
now, what other tools do I need?
very close, but sadly I need to take the transmission out again.
It took me a month to decide to take the tranny back out -- two hours to do it -- and ...
only a few seconds to actually change the part.
ready for round two....
Minoru couldn't stand the idea of having to run through a tank of bad gas...
Older style upper boot mounts.
Newer style built-in upper mount.
Lower mount (fitting over the fork lowers).
Headlight bracket modification.
Brass tubing and plastic hose used to ensure the free flow of air as the boots compress and expand.
lower mounting brackets
The spacer I managed to not include when I installed the new taller fifth gear the fist time...
laid out again
ST rack with oddly aligned turn signal mounts.
I've heard that BMW sometimes came with a BMW rag so I thought this was correct for a rebuild.
Ready for its test run next week(when I will have time to get it registered)
Done! Now I have a new thirty year old bike...
The last few bits for the ST from Rick at Motorrad
Ignition as well!
A bit of Japan