82 Brake pedal install


Information and questions on GL1100 Goldwings (1980-1983)
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Rumman
Posts: 23
Joined: Sun Aug 30, 2015 2:26 pm
Location: Daphne,AL
Motorcycle: 1982 goldwing gl1100

82 Brake pedal install

Postby Rumman » Sun Sep 27, 2015 11:49 am



Maybe a basic question, but I just don't know. My 82 gl1100 rebuild didn't come with brakes installed. Master cyclinder reservoir cracked, calipers all rusted bad. Rear master cyclinder looks good. Actually the rear caliper looks the best. How can I get the Pistons out? They are frozen in place. The brake pedal not installed. Is there a (how to) to install the pedal and spring? I have found several threads on brakes, but I am unclear on these items. Oh, can I use after market clutch lever and brake/reservoir lever?
Thanks Goldwingers!!



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redial
Posts: 1993
Joined: Mon Jan 03, 2011 1:17 am
Location: Kapunda, SouthAustralia
Motorcycle: 1997 GL1500 Spectre Red Aspencade

Re: 82 Brake pedal install

Postby redial » Sun Sep 27, 2015 11:59 pm

I am unable to help specifically, but, try brake cleaner on the pistons. You should also look at cleaning everything, (do not forget the small return hole), and look at the lines. Of course, it will all need flushing after you have cleaned. You should lubricate the pins, but that should be on here somewhere else.

Read up on this article:
"Save me from my locked brakes disaster"

Save me from my locked brakes disaster • GL1200 Information ...
Just enough pedal to lock the front and back brakes. I am at my wits end .... So why would one piston not move out from the grease gun? Top ...
goldwingdocs.com/forum/viewtopic.php?t=11977


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Len in Kapunda

The world is not going to finish today, as it is already tomorrow in Australia and New Zealand, and other islands of foreign nations such as Guam and Samoa.

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maintainer
Posts: 291
Joined: Sun Mar 22, 2015 11:39 am
Location: Houston, Texas
Motorcycle: 1977 GL 1000
1982 GL 1100 Interstate (Sold)

Re: 82 Brake pedal install

Postby maintainer » Mon Sep 28, 2015 6:21 am

The brake pedal mechanism is very simple it consists of:

The pedal has a sleeve that slips over pivot shaft connected to the bike frame. (This will need grease)
After lubing and sliding it on pivot shaft there is a big washer and a cotter pin to keep it in proper position.
Next there is a heavy action return spring this causes the pedal to return after being depressed.
Finally, there is a clevis, pin, cotter pin keeper that connects the pedal to the master cylinder and brake light switch,
1982 GL 1100 Interstate SOLD
1977 GL 1000 Standard (naked can be good, who knew?)

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maintainer
Posts: 291
Joined: Sun Mar 22, 2015 11:39 am
Location: Houston, Texas
Motorcycle: 1977 GL 1000
1982 GL 1100 Interstate (Sold)

Re: 82 Brake pedal install

Postby maintainer » Mon Sep 28, 2015 6:32 am

The brake pedal mechanism is very simple it consists of:

The pedal has a sleeve that slips over pivot shaft connected to the bike frame. (This will need grease)
After lubing and sliding it on pivot shaft there is a big washer and a cotter pin to keep it in proper position.
Next there is a heavy action return spring this causes the pedal to return after being depressed.
Finally, there is a clevis, pin, cotter pin keeper that connects the pedal to the master cylinder and brake light switch.

Sticking Rear Brake Pedal (all models)


When confronted with the rear brake staying on, many owners tend to immediately blame the hydraulics. While this may well be the cause, it could equally be a purely mechanical reason.

Due to the position of the brake pedal and master cylinder, the pedal pivot and the linkage get totally forgotten in the maintenance schedule.

Not easy to get to, and mostly hidden by the side panel, exhaust pipes etc., it's easy to see why.

But for precisely the same reason of position, they get covered with dirt, debris and soaked in the rain, making them a prime target for some serious rusting.

When I first got the Swan, the brake linkage was so rusted at the master cylinder clevis pin that there was NO movement at all! I had to remove the brake pedal and master cylinder as one unit and hammer the pin out!

Fortunately, once the clevis and the brake pedal had been de-rusted and cleaned up, there was little wear in the pivot holes. A new pivot pin and we were good to go with the rebuilt master cylinder.

But how to stop this mess re-occuring?

First of all, the brake pedal pivot hole had a chamfer put on both the ends, the pivot cleaned up and the pedal hole de-rusted.

A thin 'O' ring was slipped on to the pivot, the pivot well greased with a copper based grease (that is what looks like rust in the pictures), another 'O' ring slipped on the outside and then the big washer and split pin. The idea being to seal out the water in the first place. The 'O' rings were thick enough to just be causing a slight drag on the pedal as it was moved

To seal off the clevis I used some self-amalgamating tape such as electricians use and fashioned it into a sort of boot around the clevis. Obviously it needs to be loose enough for the linkage to move, but tight where it is wrapped around the pedal and the top of the clevis. With plenty of grease in there, that should last for a good while.

While we are still in this area, you can note the adjuster and lock nut. This is where the pedal height is adjusted from before you wrap up the clevis. Undo the locknut and with the clevis pin removed, turn the clevis clockwise to raise the pedal, anti-clockwise to lower it. Remember to do up the locknut afterwards!

Also note that the master cylinder mounting bolt holes were filled in from the back with some epoxy filler to try to stop water entering and causing corrosion.

(TIP: I used a long rod about 8mm diameter with a slot cut down it in the end. A piece of 600 emery cloth about 25mm wide and 100mm long was slipped into the slot and wrapped around the rod. Put this in your drill and gently hone the rust out! Simple!)
rear brake boot 5 [/img]



1982 GL 1100 Interstate SOLD
1977 GL 1000 Standard (naked can be good, who knew?)

Rumman
Posts: 23
Joined: Sun Aug 30, 2015 2:26 pm
Location: Daphne,AL
Motorcycle: 1982 goldwing gl1100

Re: 82 Brake pedal install

Postby Rumman » Mon Sep 28, 2015 12:30 pm

Thanks all. I am ordering new steel braided brake lines first. Then look at new master cyclinder reservoir lever. I am going to soak each caliper in carb Cleaner to try and get pistons out without harming them.
I had her cranked yesterday and wanted to ride so bad.




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