Greg's GL1100 Winter Project


Information and questions on GL1100 Goldwings (1980-1983)
  • Sponsored Links
User avatar
Oldbear
Posts: 294
Joined: Fri Jun 24, 2011 7:02 pm
Location: Linden, Alberta, Canada
Motorcycle: 1983 GL1100A Aspencade

Re: Greg's GL1100 Winter Project

Post by Oldbear » Sun Mar 03, 2013 1:58 pm



Great work on the restoration. I too feel the pain of the snow; we almost got to the point where I could have reached the main road - via the sidewalks :lol:


My wife is the greatest - she won't let me sell my bike - I'm less grumpy when I ride...

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Sun Mar 03, 2013 6:48 pm

Thanks for the posts patbrandon1 and oldbear. Always good to hear from a fellow canuk... also patiently waiting for spring to arrive.

Today I got stalled out with electrical issues ... first I hooked up the starter solenoid after wiring in a new 30A fuse (got rid of the dog bone fuse) ... I have not purchased a new battery yet for the project bike, but I have a spare battery from our RV handy, so once I had the starter solenoid wired, and my RV battery hooked up I though I'd get some juice flowing thru the electrical. I've never owned a goldwing before so don't know what is normal or not ... when I turned on the key to start position the green nuetral like came on, red suspension warning light initially came on but then turned off ... however the oil warning light comes on and stays on ... not sure if this will go out once it is started or there is oil pressure built up. Then I tried cranking the bike over ... the starter solenoid went "CLICK" but nothing ... no starter moter turning over ... I got out my multi meter and measured the voltage present on the two main terminals on the solenoid when active ... and guess what .. no voltage on the starter side when th esolenoid goes "CLICK" ... so I have a problem with the solenoid...

As a sanity check I disconected the starter motor cable from the solenoid and touched it to the hot of the battery, and except for some sparks nothing ... I got out my jumper cables, bypassed the ground cable from battery to the frame and was able to turn the starter over ... so I suspected I had a second problem in that the ground cable was not providing a good ground to the bike frame and engine. I removed it and stripped back some of the insulation and once again cleaned and soldered the terminals to the copper wires... I then tested the cleaned up ground wire and was able to get the starter to turn over by toucing hot and ground cables directly to the battery ... one problem solved ...

So I decided to tear it apart and find out why it was not working ... here is what I found... and what I did to fix it and get it working like new ...
To take the solenoid apart you'll need a soldering iron ... This is the starter solenoid for a 1980 GL1100. It has a plastic cover over the 4 terminals, and a flip up cover over the "dog bone" 30 A fuse ... I've already wired in a new 30A fuse, so only the two inner spade terminals closest to the solenoid posts are needed / used to activate the solenoid.

GL1100 Starter solenoid 1
GL1100 Starter solenoid 1


GL1100 Starter solenoid 1
GL1100 Starter solenoid 1

To take the solenoid apart, the first thing you do is take a flat blade screw driver and pry up on sides of the plastic piece that covers the spade terminals. It will pop up and move up and clear of the main solenoid body. Once you have the plastice teminal cover removed you can loosten and remove the two philips screws at the top of the solenoid ... then comes the tricky part ... to pull the two halves of the solenoid apart you need to unsolder the two solenoid terminals... if you lay the tip of your soldering iron so that it bridges across the solder blobs on both terminals at the some time it will allow both solder pads to become molten and you can then lift the top half of hte solenoid clear of the bottom half .. I happend to have a desoldering tool (solder-pullit) which will clean/suck up the molten solder present on terminals ... any way the goal is to seperate the two halves of the solenoid ... here is a picture of the two terminals with all of the solder removed ... there are two holes visible and thru them are the wires going to the solenoid.

Solenoid terminals - desoldered/cleaned 1
Solenoid terminals - desoldered/cleaned 1


Solenoid terminals - desoldered/cleaned 2
Solenoid terminals - desoldered/cleaned 2

Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

dayser7
Posts: 36
Joined: Wed Sep 22, 2010 11:58 pm
Location: Highmore SD
Motorcycle: 2001 GL 1800 Goldwing
Contact:

Re: Greg's GL1100 Winter Project

Post by dayser7 » Sun Mar 03, 2013 6:54 pm

Man you are the original Handy Andy...amazing...I would not have even considered trying to fix it. Thanks Greg..

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Sun Mar 03, 2013 9:57 pm

Once the solder is clear of the two terminals the solenoid halves will come apart ... here is what you'll find... the lower half with the solenoid and long straight wires that are what you just unsoldered ... and the upper half with the copper "crow-bar" pieces ... which are supposed to connect together when the solenoid is activated...

solenoid repair 1
solenoid repair 1

A starter solenoid is pretty simple ... the activated solenoid generates a magentic field which "pulls" a solenoid plunger/shaft terminal down which will act like a "crow bar" and bridge or short the battery and starter terminals together... when you release the starter button, the magentic field collapses, and the plunger solenoid returns to its at rest positon with the help of a spring ... breaking the connection of the battery to the starter.

solenoid repair 2
solenoid repair 2

What I found is that one side of the plastic body of the upper half of the solenoid had melted which resticted the movement of the "crow-bar" piece attached to the plunger ... the melted plastic simply acted as an obstruction to allowing the shorting bar to join one terminal to the other...

So the fix was simply to remove the melted plastic obstruction... once the nuts are removed the two copper terminals studs can be pushed out, leaving the "copper crow bar piece" ... after a bit of scraping/cutting with a sharp knife, the plastic obstruction was removed and the crow bar pieces is allowed to move freely. You can sse the result of cleaning / scraping the melted palstic from the left hand side of the crow bar in the next two pictures..

solenoid repair 3
solenoid repair 3


solenoid repair 4
solenoid repair 4

Once the plastic obstruction is removed you can put things back together....

join the lower solenoid assembly to the upper half by fitting the two wire leads thru the two small holes.... and once the two halves are screwed together you re-solder the two wires to the terminals.

solenoid repair 5
solenoid repair 5


solenoid repair 6
solenoid repair 6

and you are done .... this is what i found and fixed on my starter solenoid ...
Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

User avatar
WingAdmin
Site Admin
Posts: 18354
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: Greg's GL1100 Winter Project

Post by WingAdmin » Mon Mar 04, 2013 1:27 pm

Keep in mind that once you do get it started up, you'll need to run it for a while with the radiator cap off, as it burps all the air out of the engine. Stand ready with at least another quart of coolant and add it every time it burps air out, to keep the level up. It will take a few minutes of this to get all of the air out of the system.

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Mon Mar 04, 2013 5:41 pm

Thanks for the note on initial startup WingAdmin. Much appreciated.

I hope to be doing my initial start up later this week. Will keep all posted.
Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Greg's GL1100 Winter Project

Post by littlebeaver » Mon Mar 04, 2013 6:08 pm

I don't recall you mentioning the 3 yellow wire plug out of the stator,,,Has it been repaired? I would also check the other plug under it too, it goes to the pulse generator, it gets dirty..Check the ohm's to it..

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Mon Mar 04, 2013 6:20 pm

Littlebeaver a week or so ago I did remove the two connectors you asked about.. soldered the stator wires and the pulse gen wires directly. Thanks. Do most owners also directly solder in their voltage regulators? I have not done that one yet.
Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Greg's GL1100 Winter Project

Post by littlebeaver » Mon Mar 04, 2013 6:24 pm

Gosh darn it I just read it, sorry about that,,,My bad...

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Mon Mar 04, 2013 10:04 pm

Not a problem Littlebeaver ...

Well after a 7 year rest the BIKE ENGINE IS ONCE AGAIN RUNNING !

Tonight I put some fresh gas in the tank, made sure petcock was on, checked plugs etc, full choke on and cranked it over ...

It took a while for gas to get into the carbs but she eventually coughed and then started right up ... at a very high idle ...

Shut her down and I backed off the main idle screw then restarted and tweaked the idle screw to get the idle down to around 1K RPMs...

lot of smoke initially from sitting for so long ... grease/oil burning off the pipes etc. .... but after a couple of minutes the air cleared and all looked ok..

I followed wingadmins advice and let the rad warm up and added fluid as it burped out the air ...

I did this while I was doing my HAPPY DANCE ... I am one happy camper ... the Engine sounds very good ... no bad noises and the bike idles very nicely, and has smooth and responsive acceleration ...

I have attached a movie of starting it up after it had warmed up ... as you will see the key/ignition switch is a bit flaky and needs attention ... the sound on the movie is not great ... does not do the bike engine justice as it makes the bike sound like a diesel tractor ... I will try another one with the camera in a different position...

Ooops ... I will need to figure out how to upload a movie file as this post will not allow me to attach an MPG file ... sorry ...
Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Greg's GL1100 Winter Project

Post by littlebeaver » Mon Mar 04, 2013 10:54 pm

Greg, sounds great man,,upload your video to youtube then play it on youtube after you have uploaded it, go to the top of the page and right click and copy the video's address then open this post back up and reply to this post, stating here is your video and paste it.. That's it.. :D I think :shock: Those idle jets holes are so tiny it's hard for me to believe the side jet holes got clean even after boiling it and with air pressure..That's why I pull them.. But if the boiling does clean them , then more power to you man..Good job..If it's idling good then maybe they got clean.. :D

User avatar
patbrandon1
Posts: 471
Joined: Mon Mar 26, 2012 1:39 am
Location: Bay City, Michigan
Motorcycle: 1987 GL1200I
1982 GL1100I (Crashed)
1981 Honda CM400C (Sold)
Contact:

Re: Greg's GL1100 Winter Project

Post by patbrandon1 » Mon Mar 04, 2013 10:59 pm

Greg, please post a vid of that happy dance too, okay? :D :D :D We are all dancing with you. Congratulations on a job well done. Do you have a YouTube account. It's easy to set one up, then upload your video there, and post the link on your message, and we can see the vid. There may be another way to put vids on here, but I link mine to YouTube. If there is an easier way, I hope someone chimes in to tell us how.

User avatar
patbrandon1
Posts: 471
Joined: Mon Mar 26, 2012 1:39 am
Location: Bay City, Michigan
Motorcycle: 1987 GL1200I
1982 GL1100I (Crashed)
1981 Honda CM400C (Sold)
Contact:

Re: Greg's GL1100 Winter Project

Post by patbrandon1 » Mon Mar 04, 2013 11:08 pm

Oops, sorry littlebeaver, I must have been typing while you posted. So YouTube is the best way to post vids on here?

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Greg's GL1100 Winter Project

Post by littlebeaver » Mon Mar 04, 2013 11:19 pm

No man it's cool,, I happen to love other guys video's, you learn alot from them..That freakin Admin. guy does some really good one's I can't speak as well as he can so I add graphic's, it's easier for me....I'm brain dead ... :lol: :lol: too many concerts back in the day...Too many days of sitting around in a room getting stoned and jamming out.. :shock: I really want to see his video,,I have become a fan of Gregs man... :D

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Wed Mar 06, 2013 5:28 pm

Thanks for the info on how to post a video patbrandon1 and littlebeaver...

so here goes ... here is the link to the youtube video I uploaded ... I'll have to work on the video for my "happy dance" :-)

If this works I'll try a couple more .. hopefully with better sound .. closer to engine... engine really does sound a lot better than on the video ...

warms up nicely, fan comes on and off, and stator/regulator is charging battery @ 14.75V





greg
Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

User avatar
patbrandon1
Posts: 471
Joined: Mon Mar 26, 2012 1:39 am
Location: Bay City, Michigan
Motorcycle: 1987 GL1200I
1982 GL1100I (Crashed)
1981 Honda CM400C (Sold)
Contact:

Re: Greg's GL1100 Winter Project

Post by patbrandon1 » Wed Mar 06, 2013 8:07 pm

It's gotta feel pretty good to have it purrin' after all the work you've put into her. What did you name her? I'll be watchin for the happy dance. :D :) :D :) :D :) :D :) :lol: :lol: :lol: <<<<<<< That's my little happy dance for you.

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Greg's GL1100 Winter Project

Post by littlebeaver » Wed Mar 06, 2013 8:26 pm

Yeah it's the camera's fault not yours, I bet it's a Vivitar one isn't it?,,,mine made videos that sounded like that and it drove me to drink...then,, I had to break down and purchase a little bit better camera,,,I think the alternator jacks with it somehow...don't know...but maybe it will get better outside...Looks great though Greg and thanks for posting a video..Now about that happy dance..I really want to see that video...Hey hey have a few brews and get that happy face on before you shoot the video.. :lol:

User avatar
Fulcrum
Posts: 181
Joined: Thu Mar 07, 2013 1:54 pm
Location: The Falls, Texas
Motorcycle: 1982 GL1100

Re: Greg's GL1100 Winter Project

Post by Fulcrum » Sat Mar 09, 2013 2:02 am

Wow, amazing thread. And amazing progress! I'm sure this is inspiration to all of us. I have a feeling I'm gonna be picking your brain alot if you let me. Great job!

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Greg's GL1100 Winter Project

Post by littlebeaver » Sat Mar 09, 2013 9:54 am

Yeah man,,Greg has posted a lot of photo's of his progress and that's the coolest thing, it takes patience and extra time to document everthing and go through the time to post a photo or take a video,,,Often, I am not happy with my video's but I post them anyway...It makes this site worth coming to when someone does though, we have something to look forward to....actually seeing something in procress always helps to determine a problem or issue..It seems like in your video you were throttling the engine but I didn't see the tach run up as it should.. I found that odd but it's clearly operating... :?

mfrancis
Posts: 22
Joined: Sun Mar 11, 2012 2:53 pm
Location: Dayton, Nevada
Motorcycle: 1983 Honda Gold Wing Aspencade

Re: Greg's GL1100 Winter Project

Post by mfrancis » Sat Mar 09, 2013 4:57 pm

I keep checking on this post because I love what you are doing and hope to one day be able to do this myself. keep up the Great job you are doing and I hope you keep the pics coming. Cant wait to see the end result

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Sat Mar 09, 2013 7:06 pm

Fulcrum I love your profile picture ... Is that hunk of meat in the shape of the state of Texas ?
Does not matter.. Cool pic... Wife and I had BBQ steak tonite even though it was freekn cold outside... Thanks for the positive post...

Littlebeaver.. Thanks for comments...You are very observant .. I notice the same... The tach is very sluggish... I rev the engine and the tach needle does not move up and down quickly like I expect... Was thinking this was normal for a goldwing... It does move up and down with gas throttle but tach will only Match engine RPM if I leave it at that speed for 20-30 seconds ... Suggestions /comments as to what to check are welcome.


Mfrancis... and Fulcrum .... Thanks for checking on my thread...and positive comments and support... I hope this post inspires others as well.. Lot of great helpful folks on this site... Feel free to ask your question and you will get enthusiastic response.

I have a few pictures and updates to make later this weekend...

Greg
Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Sat Mar 09, 2013 7:17 pm

Patbrandon1and Littlebeaver here is a guy showing all how to do happy dance... Enjoy...





I just don't have guts to post my happy dance on this thread... Perhaps when spring arrives I,ll be inspired once again to do so....

Have not named the bike... Never really thought to do so.... Will wait and reflec a bit on that one...

Greg
Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

User avatar
Greg_C
Posts: 142
Joined: Sat Dec 22, 2012 10:01 am
Location: Nova Scotia Canada
Motorcycle: 1980 GL1100 Interstate (sold)
1976 GL1000 (WIP)

Re: Greg's GL1100 Winter Project

Post by Greg_C » Sat Mar 09, 2013 7:20 pm

Fulcrum.. I get it is shape of USA ... Was distracted by the nice cut of beef... My bad...
Current Rides:
1976 GL1000 (WIP)
2004 Dodge Ram 2500 Cummings Diesel - Camper puller
2006 Toyota Corolla - My Daily driver
Past Rides:
HMCS Assiniboine (DDH 234)
1980 Porsche 911 SC Targa
1979 MGB Roadster
1980 GL1100 Interstate

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Greg's GL1100 Winter Project

Post by littlebeaver » Sat Mar 09, 2013 7:29 pm

Oh Wow :shock: ....You are giving me idea's...should never do that to the Beave...I'm not afraid to do the Happy Dance...Never..I'm not afraid of Nuttin.. :D That was funny...I bet you are happy to start that sucker...

User avatar
littlebeaver
Posts: 4452
Joined: Mon Sep 21, 2009 6:11 pm
Location: Kansas City, Kansas
Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Greg's GL1100 Winter Project

Post by littlebeaver » Sat Mar 09, 2013 10:00 pm

Hey Greg,, I think I met my match,,,this Fulcrum fella and his Steak Avitar man...what a trip..did you notice florida and Arkansas and Minnasota seem to be all fatty and such... :lol: well have taken these tachometers apart in the past...I'm told that graphite spray cleans it up right..I used a qu tips and alcohol to clean moving parts inside,, Don't use oil...on the tac...I did that and laughed my rear off because it was all slow motion... :lol: do some research here on it in the seach section..



Post Reply