Restoration of a 1983 Honda GoldWing (GL1100-Interstate)

Information and questions on GL1100 Goldwings (1980-1983)
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Motorcycle: 1983 Honda GL1100-Interstate

Restoration of a 1983 Honda GoldWing (GL1100-Interstate)

Postby timothy1027 » Sun Dec 18, 2011 10:14 am

Restoration of a 1983 Honda GoldWing (GL1100-Interstate).
In July 2011, I purchased the bike (which had only 76,000 miles on it), from a retired millwright near Baltimore, MD. He was a "junk collector" type of guy who was "cleaning up" his back yard. He had let the bike sit outside for several years, supposedly under a cover, but the bike still needed extensive work. After I got the bike back to my shop, I realized why the seller loaded it onto my trailer using a bobcat. The bike would not even roll because, both wheels were locked up (from rusted brakes) AND the engine was locked up! I spent several hours cleaning the bike (...used a pressure washer), installed a new (AGM) battery and to my surprise, all the lights worked, but I only got a "click" from the starter. The seller had told me that the bike was "running" when he parked it (years ago). I then tried to turn the engine over with a wrench on the crankshaft, still no dice. I then pulled the cylinder heads and found that the #4 piston was rusted to its' cylinder. For some reason only that cylinder was affected by rust. There was no rust in any of the other cylinders! Over the next several DAYS, I had to use a lot of elbow grease, a sledge hammer, gallons of WD-40 & even an oxyacetylene torch, but I eventually got the crankshaft to spin freely. I was really NOT in the mood to pull the engine out of this BIG BEAST! I found insect & rodent nests in many of the crevices in the bike. They really LOVED the air filter housing! The fuel tank had some really NASTY black, gooey stuff in it. I got some instructions from Randakk on how to clean it. I had to unclog the fuel lines inside the tank. I used .062" diameter piano wire and aerosol brake cleaner to clean out the clogged flexible brake lines. I've made 3 special tools so far. 2 for cleaning out the bore of each brake master cylinder (front & rear). A modified ½" drive 30mm socket for removing the lock nut on the left-side of the swing arm. I think the OEM tool costs like $65.00. I paid $7.00 for materials. I will publish dimensioned drawings of the tools if desired by members (I once worked as a tool designer). I lapped the valves for the heads. They are otherwise usable. I plan on doing a carb rebuild in the near future (BIG JOB). My only constraint is cash these days. I have 52 digital pics of the restoration job so far. I have found MANY good resources on the Web! I expect this bike to run like a "Swiss Watch" when I'm through with it! :-)
To be continued...
Tim Barber
Barber's Workshop

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Re: Restoration of a 1983 Honda GoldWing (GL1100-Interstate)

Postby WingAdmin » Sun Dec 18, 2011 6:56 pm

Wow, that is quite a project! post some of your pictures in your member pictures area for us to have a look at!

I wonder if that one cylinder had its exhaust valve open, and moisture got into it that way over the years?

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