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Old 03-09-2010, 10:47 AM   #1
ski_bum OP
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Oddometer: 10
1983 R80 G/S - Rebuild

So here we go....... My younger brother whom shall remain nameless took his stock 1983 R80 G/S off a switch back on Cotton Wood Pass during a moto trip to Crested Butte. Though he survived, all be it pretty beat up ( no broken bones but some severe nerve damage to his shoulder), the bike did not fair so well. The front end completely crumpled, forks, fairing, and dash. The pannier rack and one of the cases were both badly damaged. The frame appears to be straight.

Here is a list of what I would like to do:
-CR500 front end
-CR500 Front wheel
-CR500 front brake
-Vapor Moto Computer.
-Trail tech front light


And probably a variety of other stuff that i will encounter along the way. Ideally i will get this bike into dirt road riding shape by spring melt off.

I have previous moto experience when i did a frame off restoration of a '76 Yamaha xs 500. But any technical help would be greatly appreciated. Also opinions on what else I should do to make this a good solid daily rider.

I will get pictures up soon but need to mess around with file size.
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Old 03-09-2010, 11:08 AM   #2
ski_bum OP
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So the first thing that I could use some help with is the fitment of the CR500 forks to the G/S frame. I pulled the old forks off last night and it looks like i need some spacers for the of the stearer. Is it possible to swap out the old steerer tube into the CR triples?
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Old 03-09-2010, 11:19 AM   #3
Gravytrain
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How much travel do those forks have?
How much longer than stock are they?
Do you plan on modding the rear to match?
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Old 03-09-2010, 11:24 AM   #4
StephenB
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Welcome to the asylum. Glad your bro' is ok, things just happen sometimes.

Before you start spending (I guess you have already) you have to make sure your frame's still straight. You think it is but maybe it isn't. You said "crumpled" so I assume the worst. Here's what I would check first: steering head gussets, they should be completely and absolutely flat without even a smidgen of distortion.

Here are some real photos of a crumpled front end:








Look at the two gussets welded to the stearing head: in this case the RH side is about straight, LH side is curled (click the picture for higher resolution).







The second picture looks up from below the steering head (it sits right under the steering lock).

You should also make sure that front and rear wheel track, with both wheels installed and a long wooden plank or something else straight. This is only a rudimentary check but if any of that is suspicious you ought to have the frame straightened firat.

This I think you have to look at to be sure your money isn't wasted.

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Old 03-09-2010, 11:30 AM   #5
Solo Lobo
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somebody already put a Honda front end on a G/S... was it crash?

while it has already been done before, the big thing to remember is that the off-set from the center of the triple clamp stem to the forks tubes is 36mm (or 38mm?) on BMW's and less than 20mm on many others... you would lose steering lock as well as changing the geometry...

That said, go for it and post pictures!
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Quote:
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your bike is suitably dirty. Well done.
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So I sold my GS and went shopping for a G/S!
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Old 03-09-2010, 11:57 AM   #6
Gravytrain
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I can save you some time and effort.
Just swap me for my XRL
[IMG][/IMG]
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Old 03-09-2010, 12:37 PM   #7
Gravytrain
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Practice this line.
Dear, I HAVE to send the frame to HPN to make sure it is straight and safe.
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Old 03-09-2010, 12:47 PM   #8
Infracaninophile
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Quote:
Originally Posted by Gravytrain
Practice this line.
Dear, I HAVE to send the frame to HPN to make sure it is straight and safe.
Corrected:

"Dear, I have decided to direct deposit some of my paycheck at Max BMW and HPN for the next 3 months".

Tom
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Old 03-09-2010, 01:41 PM   #9
Airhead Wrangler
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I've heard "the frame man" come up now and again as the best place in the states to send a tweaked frame. Anybody have any firsthand experience with these guys?

http://www.motorcycleframestraightening.com/bmw001.html
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Airhead Wrangler screwed with this post 03-09-2010 at 02:20 PM
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Old 03-09-2010, 03:31 PM   #10
ski_bum OP
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anyone know how to post pictures????
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Old 03-09-2010, 04:22 PM   #11
hardwaregrrl
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Hey ski!

You should get a site like flickr.com or smugbug.com, or some photo site like that. then down load the pics to the site, grab the url and paste it in the subject line.....here. There is a thread that explains much better than I, but I can't seem to find it.
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Old 03-09-2010, 04:26 PM   #12
Gravytrain
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http://www.advrider.com/forums/showthread.php?t=919
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Old 03-09-2010, 07:07 PM   #13
ski_bum OP
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hey thanks guys...... i am in the process of creating a Flickr account. I will have pictures up soon.

now onto the build.....

anyone know the spec on the BMW steerer tube?

I am thinking that I might swap the steeres from the bmw fork to the cr fork......possible????

oh and i think that the frame is straight see the pictures that i will put up on flickr....
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Old 03-09-2010, 07:10 PM   #14
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ok.... as promised here is the link to flickr

http://www.flickr.com/photos/45928813@N03/?saved=1
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Old 03-09-2010, 07:25 PM   #15
Gravytrain
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What is your plan for the fork length? Your new forks look way longer.
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