forks- if you have to rebuild 'em make it worthwhile


Information and questions on GL1200 Goldwings (1984-1987)
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deanbw
Posts: 278
Joined: Sun Nov 30, 2014 2:30 am
Location: puyallup,wa.
Motorcycle: 1986 gl1200a aspencade . Honda xl600r, '68 z50, '82z50, '80cx500c, '00 klr250

forks- if you have to rebuild 'em make it worthwhile

Postby deanbw » Fri Apr 17, 2015 1:46 am



So I am slowly getting to the "going back together" stage of my aspy's "clean up"....ha, clean up.
Well anyway i thought if I was going to do the forks i should make it worthwhile while the bike is stripped down.
I went through the parts fiche and bought all the parts available, new o rings (some o rings i bought chemical resistant from mc master), seals, bushings,seal rings, copper washers and even new "TRAC" decals. I think if your going to do this job you should do it right right and do it once, to get all the parts is only about 130 bucks for parts, if you amortize that over the life of the forks it's dirt cheap.
This is what I started with -

I got them apart and then cleaned, glass beaded, polished and clear coated lower tubes and trac valve housing.
Now it was time to put all the shiny stuff together-

Once I got that done new upper and lower bushings were installed, new seals and dust boots, then last but not least...the new trac decals-


So in the end, I feel the money is well spent to know I have forks that are now nearly new, and will look good for years to come.



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Aussie81Interstate
Posts: 682
Joined: Thu Nov 27, 2014 2:34 am
Location: Penrith Australia
Motorcycle: 1982 CX500 Turbo (restoration project)
1981 GL1100 Interstate (sold)
1988 GL1500

Re: forks- if you have to rebuild 'em make it worthwhile

Postby Aussie81Interstate » Fri Apr 17, 2015 3:52 am

Awesome job, well done. :)

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CMReynolds1
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Location: Oregon
Motorcycle: 2013 F6B

Re: forks- if you have to rebuild 'em make it worthwhile

Postby CMReynolds1 » Fri Apr 17, 2015 8:14 am

Very nice, Sir! Also, VERY SMART!!!
Ride Safe,
Taz


TF 116, RivRon 512, Can Tho, S. Vietnam, 8/66-/9/68, GM(G)2

tvtruth
Posts: 25
Joined: Mon Apr 28, 2014 5:03 pm
Location: Aliso Viejo, California
Motorcycle: 1981 GL1100 naked
1987 GL1200I

Re: forks- if you have to rebuild 'em make it worthwhile

Postby tvtruth » Fri Apr 17, 2015 4:08 pm

What was your process to get them so shiny?

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alanc1100
Posts: 71
Joined: Thu Aug 26, 2010 4:51 am
Location: Lakewood, Wa.
Motorcycle: 1986 GL1200A Aspencade

Re: forks- if you have to rebuild 'em make it worthwhile

Postby alanc1100 » Fri Apr 17, 2015 7:32 pm

Dean, Nice work! What is your polishing secret? Please let us know...

Alan

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deanbw
Posts: 278
Joined: Sun Nov 30, 2014 2:30 am
Location: puyallup,wa.
Motorcycle: 1986 gl1200a aspencade . Honda xl600r, '68 z50, '82z50, '80cx500c, '00 klr250

Re: forks- if you have to rebuild 'em make it worthwhile

Postby deanbw » Sat Apr 18, 2015 1:26 am

tvtruth wrote:What was your process to get them so shiny?


ok, I buff them on a 10inch buffing wheel -
1- clean first then mask holes
2- glass bead to remove factory clear
3- use black compound to cut through glass bead finish and smooth part back out, use this until you start to bring some shine back to part.
4- I dont have two wheels so I rake wheel and apply green compound, white is finer and brown (red) is for aluminum but I like green best. keep plenty of compound on wheel until color(shine) really starts coming back up, rake wheel often, keep wheel from packing up. as shine gets brighter you can use less compound for finishing.
5- use a good hand polish like meguiars hot rim and aluminum polish to bring up final shine and get rid of buffing wheel pattern.
6- remove masking from holes, wash with soap and water,not detergent, something like ivory soap
7- wipe down with acetone to remove any film left, re-mask holes
8- warm part - (just barely) spray clear coat. use a very light first coat, clear will run very easy on the smooth finish,use as few coats as possible 3 should do it, thin coating stays on better than thick.

NOTE- the clear will kill a little of the shine but it gives a nice factory look and wont dull, which means I dont have to keep polishing, so to me it's a no brainer.

sounds worse than it is, goes pretty good really.
The "TRAC" valve part is just glass beaded and clear coated. I use gloss, but to each is own.

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Rednaxs60
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Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD, 2008 GL1800

Re: forks- if you have to rebuild 'em make it worthwhile

Postby Rednaxs60 » Fri Jan 08, 2016 3:14 pm

deanbw - Had my suspension redone and it was noted that the piston case boot(s) 51442-MC7-003 were in rough shape. Is it necessary to remove the rear piston case to change the piston case boot(s)? The shop mentioned I'd be able to replace the boot(s) with the rear piston case on the fork(s).

Here is your photo showing parts:



Cheers

Ernest
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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deanbw
Posts: 278
Joined: Sun Nov 30, 2014 2:30 am
Location: puyallup,wa.
Motorcycle: 1986 gl1200a aspencade . Honda xl600r, '68 z50, '82z50, '80cx500c, '00 klr250

Re: forks- if you have to rebuild 'em make it worthwhile

Postby deanbw » Fri Jan 08, 2016 6:07 pm

the cylinder (piston case) has a flange on one end, I'm not home to look and don't remember which way it went, but if the inside is the end without the flange (mine has a flange though the parts fiche shows it straight with grooves on both ends) then yes you can, but pulling the cylinder out to do either end is no problem, even if it is on the bike and has to go to the disk I think there is room.

just pull the caliper and slide it out.

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Rednaxs60
Posts: 726
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD, 2008 GL1800

Re: forks- if you have to rebuild 'em make it worthwhile

Postby Rednaxs60 » Sat Jan 09, 2016 11:22 am

deanbw - thanks for the answer. Have ordered the boots (rubber grommets), should be in this week. Will be doing the front rotors and pads this week as part of my refurbishment of this bike. Thanks again. Cheers

Ernest


"When you write the story of your life, don't let anyone else hold the pen"

Ernest


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