Lost all power...


Information and questions on GL1100 Goldwings (1980-1983)
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joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Lost all power...

Postby joecvs » Tue Jul 03, 2012 9:22 pm



I have lost all power to my 1983 GL1100 interstate. After starting it up, trying to get it warmed up, and running it for about 2-3 minutes, (I heard a 'clunk' -- sounded like it came from somewhere under or near the seat---and then nothing! When I attempt to turn the ignition key, no lights, no horn, no instrument panel light-up---zippo. I had the master fuse tested and it came back good....the dogbone fuse looks good (no breaks, etc..).....any thoughts as to my next series of steps....I appreciate any help as summer is slowly passing me by...thank you ....



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seabee_
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Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Tue Jul 03, 2012 9:31 pm

Start by making sure the battery tests good. Then start checking for voltage from the battery thru the dogbone fuse an up to the fuse box. Then we can go from there. Do you have a service manual or Haynes manual for the bike.

The clunk sound is of concern. Before starting the bike pull the pluga and then you need to turn the motor over by hand. NOT THE STARTER. Need to be sure you don't have hydrolock or seized motor. Postback what youfind.
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Tue Jul 03, 2012 9:40 pm

Thank you for the reply...I shall try that advice and will post as soon as possible...

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Tue Jul 03, 2012 9:42 pm

Please advise----how do you turn over the motor by hand...versus the starter..?

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seabee_
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Location: sterling heights, mi
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1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Tue Jul 03, 2012 10:10 pm

There a a few ways. You can remove the cover plug on the stator and use a socket to rotate the motor. ONLY TURN THE BOLT CLOCKWISE-TO THE RIGHT. Turn it counterclockwise and you loosen the stator bolt. The other way is to remove the timing belt cover and use a socket to rotate the cam pulley the same way. When you remove the spark plugs see if the cylinders filled up with gas. We can cover how this happens later. After you are sure the motor rotates ok then you can use the starter. If it hydro locks and you try to turn it over with the starter you can bend a rod.
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

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WingAdmin
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Re: Lost all power...

Postby WingAdmin » Tue Jul 03, 2012 10:52 pm

To rotate the engine by hand:

1. Remove the stator bolt cover on the rear of the stator. This will expose the bolt used to rotate the engine.

Image

2. Once the cover is removed, clean the threads and put it aside.

Image

3. Fit a socket and ratchet onto the stator bolt on the back of the engine. It is VERY important that you rotate the engine CLOCKWISE only - as if you were tightening the bolt. Rotating the engine backwards can cause the stator bolt to loosen off! Try rotating the engine so that you get a feel for it. You will be rotating against the compression of the cylinders - if you have a hard time turning it, try turning it slower, or remove all the spark plugs, which will eliminate the compression resistance.

Image

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seabee_
Posts: 494
Joined: Sun May 29, 2011 8:17 pm
Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Tue Jul 03, 2012 11:02 pm

Hey wingadmin, I was waiting for you to drop in on this post with the pics. I didn't have access to them on my Android. I thought I was going to have to wait till I got off work and on my laptop. ;)
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Wed Jul 04, 2012 7:35 pm

Thank you for your replies....I have to keep borrowing someone else's computer (and hence the delay in 're-responding')...since my mechanical abilities are somewhat limited I am going to start with the battery and will get it tested to measure the appropriate (or lack of) charge. Because I have had the bike on a battery tender for probably toooo long of a stretch, I will make this my first step in the repair process....will keep posting as soon as I can get a day off which is towards the end of this week..... thanks again..!

Joe.Onebatterycheckcomingup.com

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littlebeaver
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Re: Lost all power...

Postby littlebeaver » Wed Jul 04, 2012 9:50 pm

My favorite advise is to check the ground at the frame too, one of these times I will get it right.... :lol: The only reason I say this is because I have seen what a bad ground wire can do.. :D Good luck

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seabee_
Posts: 494
Joined: Sun May 29, 2011 8:17 pm
Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Wed Jul 04, 2012 10:09 pm

Good mention littlebeaver, I almost forgot about a bad ground connection. A lot of times, that's a no. 1 cause.
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Fri Jul 06, 2012 7:33 pm

After hooking up a jumper cable from my car to my bike's battery (without starting the car), I found that the cause of all electrical failure was indeed the battery!. Everything lit up like Christmas in July once I connected the car's power source to the bike.... I ordered and installed the new battery today, and, now I have a different problem which I deeply appreciate any help with:

* I shut off the bike after an initial short turn over try---since it was successful --I then inspected the bolt to the stator because
a couple of days ago, after reviewing the previous posts, I looked at this bolt to know which one I would need to address if my problem wasn't the battery........At that time I noticed that the head of the cover plug to this bolt was completely gone!---as tho it had been sheared off..like it was just a big thick washer instead of a cover bolt ....I was able to simply remove it by hand and did so and at that time I didn't notice anything peculiar about the actual stator bolt itself..Also at that time I actually tried to re-screw the remaining cover plug back on, but couldn't get it started so I just gave up for the night and figured I would just order a new one somewhere down the line...........
* But today, after celebrating the success with the newly installed battery, I saw the stator bolt completely loose as tho it had untightened itself----so much loose that it was actually just hanging there.....!!!

Is this a disaster, or can I somehow re-attach / tighten the bolt myself?
How in the world does this even come loose to begin with....?

I am, as before, grateful for any corrective suggestions. Thank you..!

Joe.BatterysolvednowwhatdoIdowithaloosestatorbolt.com

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littlebeaver
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Re: Lost all power...

Postby littlebeaver » Fri Jul 06, 2012 7:47 pm

I would ask Virgilmobile here to see if he has one he can send you, send him a pm. if he does not go to ebay, the clutch cover plug is the same bolt too, also the plug in the final gear drive is the same bolt..Just so you know..I once bought a clutch cover just for the bolt..For about 15 dollars off ebay..

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seabee_
Posts: 494
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Location: sterling heights, mi
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1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Fri Jul 06, 2012 8:00 pm

It could be the PO inadvertently loosened the stator bolt and it loosened more over time.(evident by the broken cover plug) But I would think it would back out rather fast. Was it tight when you first checked it? or did it just back out? Don't run it until you know for sure it's in it's proper place.
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Fri Jul 06, 2012 8:08 pm

When I checked it a few days ago, I believe the bolt was tight--at least not loose---because when I attempted to screw back on the plug 'cover' I really didn't notice any looseness to the bolt itself......Is it o.k. to try and re-tighten the bolt ..? I am able to feel the washer just inside of the stator and am able to get the bolt started, but is there any thing that might be specific/peculiar to the tightening?....thanks...

Joecvs

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seabee_
Posts: 494
Joined: Sun May 29, 2011 8:17 pm
Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Fri Jul 06, 2012 8:44 pm

Others will chime in on this, but I would think if you torque the bolt to specs AND rotate the motor by hand to make sure things don't bind you should be ok? I'm curious as to why the bolt backed off.
Last edited by seabee_ on Fri Jul 06, 2012 9:03 pm, edited 1 time in total.
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

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seabee_
Posts: 494
Joined: Sun May 29, 2011 8:17 pm
Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Fri Jul 06, 2012 8:56 pm

After going back over all the posts I see this-
1st post mentioned a clunk and then loss of power.
Last few posts mentioned finding broken stator bolt cover plug and the stator bolt loose.
These are connected to each other. My guess (correct me if I'm wrong) the stator bolt came loose. Backed out enough to cause the 'clunk' and also broke the plug cap as you described. I'm hoping there won't be any issues with the stator coming loose as there is a close tolerance where the stator sits. The stator bolt does need to be torqued to specs
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Fri Jul 06, 2012 8:59 pm

I am off the next couple of days and I will try to replace the bolt, try to manually turn the engine and then repost....it seems like the bolt basically sheared off the head of the cover.....no idea why it came loose.....


Joe.94degreeshereandevenhotterwhenyou'renotmechanicallyinclined.com

Seabee, your post sums it up correctly.......Joe

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seabee_
Posts: 494
Joined: Sun May 29, 2011 8:17 pm
Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Fri Jul 06, 2012 9:02 pm

(had to do 2 posts because of Android) the stator needs to be checked to be sure it's in place. Then you will need to do a stator test to be sure it's working properly. Hopefully the others will join in to tell me if I'm wrong or not. Hopefully everything will turn out good.
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Sat Jul 07, 2012 8:17 pm

Regarding the task of re-attaching the bolt--I was able to get the bolt started, and fully seated back to it's original position---or as close to it as possible...with it firmly in place I was able to turn over the engine by hand as was evident when I place the bike in gear, turned the bolt, and watched the rear wheel turn. Ya---hoooo !!! In order to guess on the tightness of the bolt, I had someone step on the rear brake pedal while the bike was in gear, and, gave it one last tightening to hope I was getting close to the correct amount of torque..

It seemed to work, as I was able to start up the bike, turn it over, and shift it into first / second gear on the center stand.

My next test will be around the block to reverify and help build back my confidence in the old beauty.

Joecvs

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seabee_
Posts: 494
Joined: Sun May 29, 2011 8:17 pm
Location: sterling heights, mi
Motorcycle: 1985 Honda Goldwing GL1200
117k miles
1977 Kawasaki kz400
1978 Suzuki GSXr750
1980 Kawasaki GPZ400
1975 Honda CB360T

Re: Lost all power...

Postby seabee_ » Sat Jul 07, 2012 9:04 pm

Be sure to use a volt meter on the battery to see what the charging volts is .
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

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Re: Lost all power...

Postby WingAdmin » Tue Jul 10, 2012 1:15 pm

The stator bolt should be torqued to 62 ft-lb. Basically, if your wrench is one foot long, you want to lift on the end of it with 62 lbs of force to torque it correctly.

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Tue Jul 10, 2012 1:26 pm

Thank you.....please tell me if it is possible to do this by hand, correctly--or near correctly--and if so, what't the best 'guess' as to 65 lbs..........just tighten it as hard as I can, while keeping it in gear and stepping on the brake?

I appreciate your advice and expertise....

Joecvs

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WingAdmin
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2007 Aspen Sentry Trailer

Re: Lost all power...

Postby WingAdmin » Sun Jul 15, 2012 8:26 pm

joecvs wrote:Thank you.....please tell me if it is possible to do this by hand, correctly--or near correctly--and if so, what't the best 'guess' as to 65 lbs..........just tighten it as hard as I can, while keeping it in gear and stepping on the brake?

I appreciate your advice and expertise....

Joecvs


Really the best thing to do is go to Harbor Freight (you're in Mentor, the closest one to you is not too far away, on Pearl Road in Parma Heights) and spend $20 on a torque wrench.

If you really want to go without, put a socket wrench with a 12 inch handle on the bolt. Put a bathroom scale under the handle, then put a bottle jack on the bathroom scale. Look at the weight registered on the bathroom scale. Raise the bottle jack until it contacts the socket wrench at the very end of the handle, then pump the bottle jack until the weight shown on the bathroom scale increases by 65 pounds. It won't be as accurate (or fast or easy) as a torque wrench, but it will get you in the ballpark.

joecvs
Posts: 12
Joined: Tue Jul 03, 2012 8:59 pm
Location: Mentor, Ohio
Motorcycle: 1983 GL1100 Interstate
1980 400 Hawk

Re: Lost all power...

Postby joecvs » Mon Jul 16, 2012 7:30 am

Thank you for the advice......I'm going to try the Harbor Freight route first....will post hopefully by the weekend or so...

Joecvs

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tedmass
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Re: Lost all power...

Postby tedmass » Wed Jul 18, 2012 4:57 pm

After you get it sorted out mark the bolt and case with a scripto marker so you can see if the bolt moves in the future.Also use lock tight on the threads :) .


Be carefull out there


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