BMW · BMW airhead (/5 /6 /7, R45-R100 1969-1995)

R80G/S / R80ST

Library entry covers 1980-1987

23 factory 45 guideline

Published source

BMW Repair Manual R 80 G/S (BMW Motorrad GmbH, Service Department), 00 00 139 BMW Service and 00 00 149 BMW Inspection; scan hosted on Scribd

Factory service manual. Covers BMW R80G/S repair manual (BMW Motorrad Service Department, 1980-87 monolever); service every 7500 km (5000 mi), inspection every 15000 km (10000 mi).

Open the source

68 items for a 1980 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead valve, pushrods, adjustable tappets
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Shaft
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1980 BMW R80G/S / R80ST

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 1,000 mi

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

On the road: every 10,000 mi

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Check and correct tightness of bolts and nuts. Factory: 00 00 139 / 00 00 149: at every inspection

Every 1,000 mi or 6 months

2 items

Check gearbox oil level

Primary and gearbox

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,000 mi or 12 months

1 item

Lubricate control cables and lever pivots

Controls and cables

Guideline

Every 3,000 mi or 12 months

10 items

Check engine mounting bolts and plates

Engine

Guideline
Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 4,000 mi or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 5,000 mi

9 items

Change engine oil

Engine

Factory

Factory: 00 00 139 / 00 00 149: BMW Service at every 7500 km (5000 mi); first at 1000 km (600 mi)
Check and adjust valve clearances

Engine

Factory

Manual: Adjust valve play. Factory: 00 00 139 / 00 00 149: at every service
Check cylinder head bolt torque

Engine

Factory

Manual: Tighten cylinder heads. Factory: 00 00 139 / 00 00 149: at every service, with the valve adjustment
Clean oil strainers / mesh screens

Engine

Factory

Manual: Check and clean oil pan / skid guard cavity and cylinder cooling ribs. Factory: 00 00 139 / 00 00 149: at every service
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Check spark plugs. Factory: 00 00 139 / 00 00 149: at every service; replaced at each 15,000 km inspection
Replace oil filter

Engine

Factory

Manual: Replace oil filter cartridge. Factory: 00 00 139 / 00 00 149: at every service
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Factory

Manual: Clean carburetor float housing. Factory: 00 00 139 / 00 00 149: at every service
Synchronize carburetors

Fuel and air

Factory

Manual: Synchronize carburetors and adjust cables. Factory: 00 00 139 / 00 00 149: at every service
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Lubricate rear swinging arm bearings and clutch cable nipple. Factory: 00 00 139 / 00 00 149: at every service

Every 6,000 mi or 12 months

4 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check final drive for leaks and bearing play

Final drive

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

1 item

Check engine breather and oil return

Engine

Guideline

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 10,000 mi

13 items

Replace spark plugs

Engine

Factory

Factory: 00 00 139 / 00 00 149: at every inspection
Clean fuel tap filter / sediment bowl

Fuel and air

Factory

Manual: Clean fuel valve. Factory: 00 00 139 / 00 00 149: at every inspection
Replace air filter element

Fuel and air

Factory

Manual: Replace air filter cartridge. Factory: 00 00 139 / 00 00 149: at every inspection
Check / set ignition timing

Ignition and electrics

Factory

Manual: Check and adjust ignition timing. Factory: 00 00 139 / 00 00 149: at every inspection
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Service battery. Factory: 00 00 139 / 00 00 149: at every inspection
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Check and adjust clutch play. Factory: 00 00 139 / 00 00 149: at every inspection
Change gearbox oil

Primary and gearbox

Factory

Manual: Change transmission oil. Factory: 00 00 139 / 00 00 149: BMW Inspection every 15,000 km (10,000 mi)
Change final drive (rear drive) oil

Final drive

Factory

Manual: Change final drive oil and oil in the rear wheel swinging arm. Factory: 00 00 139 / 00 00 149: at every inspection
Change fork oil

Front end

Factory

Manual: Change telescope fork oil. Factory: 00 00 139 / 00 00 149: at every inspection
Check steering head bearing adjustment

Front end

Factory

Manual: Check steering bearing play. Factory: 00 00 139 / 00 00 149: at every inspection
Check swingarm bushes for play

Rear suspension and frame

Factory

Manual: Adjust swinging arm bearing play. Factory: 00 00 139 / 00 00 149: at every inspection
Adjust rear drum brake and rod / cable linkage

Brakes

Factory

Manual: Check and adjust dead travel of rear wheel brake. Factory: 00 00 139 / 00 00 149: at every inspection; brake fluid level checked and brakes checked for leaks at the same time
Check wheel bearings for play

Wheels and tires

Factory

Manual: Front and rear wheel: check bearing play, inspect brake parts. Factory: 00 00 139 / 00 00 149: at every inspection

Every 12,000 mi or 2 years

1 item

Clean and grease rear suspension linkage

Rear suspension and frame

Guideline

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 20,000 mi or 4 years

3 items

Lubricate drive shaft splines / check U-joint

Final drive

Guideline
Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 30,000 mi

1 item

Lubricate clutch / gearbox input splines

Primary and gearbox

Guideline

Every 40,000 mi

1 item

Inspect timing chain and tensioner

Engine

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

4 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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Add the bike in the app and this chart loads itself, ready to log against and edit.

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