1985 GL1200 LE Maintenance


Information and questions on GL1200 Goldwings (1984-1987)
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roadwanderer2
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Re: 1985 GL1200 LE Maintenance

Post by roadwanderer2 » Thu Jan 14, 2016 5:05 pm



if you're in the market for a blind spot mirror for your bike, these are great, and they are adjustable too. i have a pair on my 1100 AND on my 1200................http://www.ebay.com/itm/Zone-Tech-Total ... PF&vxp=mtr only problems with them, you might have to super glue or use some gorilla glue around the edges of the mirror and frame so the mirror part doesn't fall out, and use some good double sided tape on the mounting plate to mirror. sometimes they come loose and fall off. i've used gorilla glue and double sided tape on mine and so far i haven't had any problems with them coming loose or falling off.

stuart.



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Rednaxs60
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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sat Jan 16, 2016 2:09 am

Another good day of progress. Picked up the parts I needed to complete the front brakes at this time. The only item to be renewed is the sleeve that allows the caliper to move and center itself. Intend to do this come February. The rest of the rebuild of the calipers went well and the front end is back together again. Bled the brakes with the Biltek 2 In 1 Brake Bleeder & Vacuum Pump Gauge Test Tuner Kit. Works well with lots of fittings. After using this kit to do the bulk of the bleed, I did revert back to old school and have my friend help me with the final bleed the old way. Pleased with the end result.

Replaced the boots for the piston collar on the rear piston case. If anyone does this, there is a small retaining clip that you may think is not needed, but it keeps the boot in place around the piston collar. These are not that big and are spring loaded when in place. Take care with them because these have to be reused. If you loose one, these "boot holders" 51445-MC7-003 are still available from Honda.

Hopefully tomorrow I'll get the exhaust back in place. I'm replacing the exhaust studs and nuts, these are after all 31 years old.

Sunday will be some more wiring, and testing the electrical mods I have done to make sure these work as I have envisioned.

Cheers

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

Ernest

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Rednaxs60
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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sat Jan 16, 2016 7:25 pm

Another good day in the garage, also got the new idlers in the mail - the last items on order, and the ones needed to put the front end back together.

Installed the new exhaust studs, got the exhaust up in place, and used the new nuts as well. New is always good and makes it so nice to do work. The picture below shows the difference.


Got the floor boards on, new starter relay installed and the battery in and hooked up. Checked the new relays I put in. Had a couple of wires switched that gave me a weird reading on the multimeter. Checked my schematic, switched the culprit wires then it went well. When engaging the kill switch the three relays lost power because the switching wires are from the coils and stator/reg-rec. System works as I had hoped.

Tomorrow will be a few wiring fixes, in preparation for starting the bike this week. Starting to see light at the end of the tunnel so to speak.

Cheers

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

Ernest

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roadwanderer2
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Re: 1985 GL1200 LE Maintenance

Post by roadwanderer2 » Sat Jan 16, 2016 7:39 pm

your doing a great job on it Ernest. you'll have that bike up and running and riding in no time.

stuart.

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Rednaxs60
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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sat Jan 16, 2016 7:52 pm

Stuart - sure feels good putting parts back on the bike instead of the other way around. Have looked at the timing belt tensioner mod again.

I have knocked the old stud completely out of the base plate. The size of the opening is approximately 0.57". One side of the opening is tapered so I will be going to my local parts place and try to find a "round countersunk" 10 mm by 25 mm. If the head is large enough, it should self-align, and all will be well. This is Mondays adventure.

Cheers

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

Ernest

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sat Jan 16, 2016 9:41 pm

Rednaxs60 wrote:Another short update. Picked up the valve cover gaskets and bolt grommets today. Changed the gaskets and cleaned up the covers. Back on and look good.

Connected the ground wires from the reg/rec to the ground bus direct this morning. Wiring is time consuming.

Have the exhaust back temporarily up in place with the help of a few 2X4s. Had to take the bike off the center stand for some reason, don't know why but it worked. Will be taking the timing belt tensioners to the son-in-law's tomorrow so I can take the old bearings off in preparation for the new bearings.

Here are a couple of pictures of the old and new exhaust gaskets.
New and Old Exhaust Gaskets.jpg
This picture shows the difference after having been installed.
Exhaust Gasket Thickness.jpg
Here is a picture of the crank pulse sensor situated above the timing belts instead of below as is the normal position.
1500 Crank Pulse Sensor.jpg
This picture shows where the crank pulse sensor is normally located.
Old Crank Pulse Sensor.jpg
That's it for today. More to follow.

Cheers

Ernest
I had mentioned that I would look and see if there was P/N on the crank sensor. It is a "TEC" sensor P/N 10305. Best I can find. Works so I'll keep it for now.

Cheers

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

Ernest

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Rednaxs60
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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sat Jan 16, 2016 10:16 pm

Throttle Position Sensor - have found where the harness from the TPS connects under the false tank. Question - can I splice into the wiring and run taps to a spot (under the travel computer) where I could test the TPS?
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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roadwanderer2
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Re: 1985 GL1200 LE Maintenance

Post by roadwanderer2 » Sun Jan 17, 2016 9:34 am

Rednaxs60 wrote:Throttle Position Sensor - have found where the harness from the TPS connects under the false tank. Question - can I splice into the wiring and run taps to a spot (under the travel computer) where I could test the TPS?
that question i cant answer. there's really not a lot of room under that onboard travel computer with all its wire harnesses under there. you might be better off asking wingadmin about that. as for the OEM part number for the crank sensor, i can get you the number for it if you'd like.

stuart.

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Rednaxs60
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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sun Jan 17, 2016 11:30 am

roadwanderer2 wrote:
Rednaxs60 wrote:Throttle Position Sensor - have found where the harness from the TPS connects under the false tank. Question - can I splice into the wiring and run taps to a spot (under the travel computer) where I could test the TPS?
that question i cant answer. there's really not a lot of room under that onboard travel computer with all its wire harnesses under there. you might be better off asking wingadmin about that. as for the OEM part number for the crank sensor, i can get you the number for it if you'd like.

stuart.
Thanks Stuart - yes please on the part number. The parts diagrams show the duals needed for the non-EFI bikes. Another fellow on this forum metioned installing two crank sensors, then if one goes down just plug in the second without remoing the interference items, iteresting concept this redundancy.

Today, it's more wiring clean-up.

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

Ernest

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roadwanderer2
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Re: 1985 GL1200 LE Maintenance

Post by roadwanderer2 » Sun Jan 17, 2016 12:39 pm

OK, there are 2 part numbers for the crank pulse sensor. one is for the single and the other one is for the dual sensors. your bike uses the single sensor which is OEM # 30300-mg9-951. the dual sensor number which is also OEM is # 30300-mg9-681.

stuart.

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sun Jan 17, 2016 12:54 pm

Thanks Stuart - will look into a spare for the bike.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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roadwanderer2
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Re: 1985 GL1200 LE Maintenance

Post by roadwanderer2 » Sun Jan 17, 2016 1:57 pm

you COULD use the dual sensor but you would have to cut, (and leave enough length) the wires and close them off. that way you can use one of the dual sensors while leaving enough room to reinstall the connector when the other side burns out or becomes faulty. you can mount both of them as long as you use only one side at a time.

stuart.

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sun Jan 17, 2016 7:20 pm

Another good garage day. Finished up the wiring in the front end, and soldered the reg/rec and stator wires.

From the Reg/Rec:

the 2 green ground wires are wired directly to the new ground bus bar;
the red/white, and yellow wires are soldered to the opposite harness wires; and
the black/white sensing wire from the stator wiring is the switch wire for the reg/rec mod relay. The black/white wire from the Reg/Rec harness is 12 VDC supply from the Reg/Rec relay.

Here are a few pictures of the progress and finished product:

This is a fuzzy picture showing the reg/rec removed to facilitate soldering of the wires:


Here is the reg/rec wire soldering complete:


Here is the reg/rec installed and wiring in place:


Here is a picture of the relays and wiring around the battery area:


One more of the battery area, relays labelled:


When I removed the reg/rec to solder the wires, I was also able to reroute some wires and such to free up room.

More on next post.

Cheers

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

Ernest

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sun Jan 17, 2016 7:29 pm

Second post to finish off the day. I have used a lot of plastic cable ties. Seemed every time I thought I was done, I would envision something better. Done for now though.

There is a 250V 0.47uF condenser attached the the red/white wire out of the reg/rec. I was thinking of going direct from the reg/rec to the starter relay with a new wire but thought better of it. Would have had to cut and splice this condenser into new wire.

Here is a picture of this condenser:


Here is where it comes out of the stator harness:


The front end wiring update is complete for now. Start on the timing belt tensioner pulleys tomorrow.

Cheers

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

Ernest

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Re: 1985 GL1200 LE Maintenance

Post by SilverDave » Sun Jan 17, 2016 10:57 pm

Ernest :
LOLOL

By now you are probably a MASTER of the soldered Western union splice and double or triple shrinkwrap !!

Looks just great !
SilverDave

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Sun Jan 17, 2016 11:25 pm

SilverDave - Did more soldering than I thought I would or needed to, but it was in preparation for soldering the stator - reg/rec yellow wires. Found that I needed quite a bit of solder to fill the wire, but I think I got it. I did double shrink wrap the stator - reg/rec wires (yellow wires). Before this I had never heard of the "western union splice", just thought it was soldering!!

Any thoughts on tapping into the TPS wiring for testing? I would run the taps to a place under the travel computer.

Cheers

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

Ernest

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Mon Jan 18, 2016 3:51 pm

Timing Belt Tensioner Rebuild - Just finished this rebuild. I had seen it in this and other forums, and was not going to do it because the idlers didn't feel that bad; however, I'm not one to shirk a challenge. Ordered the idler and it's a Gates T42105. Went to the s0n-in-law's and cut the idler off and punched out the old stud giving me an opening of approximately 0.54". The opening is countersunk on the back so I surmised that a countersunk head bolt would self-align when tightened up because the new idler would "sit" flush against the base plate. I used a 6 mm hex drive and 17 mm socket.

This picture shows the parts used with the old idler as well. You will notice that the bolt, 10 mm by 25 mm, has a flat countersunk head that should self-align when tightened.


This picture shows the countersunk hole on the back of the base plate that the bolt will fit into.


This picture shows the new idler installed and the new bolt "proud" of the base plate.


This picture shows the tensioner with the new bolt flush with the back of the base plate. I used a 24 tooth hacksaw blade to trim off the excess bolt head so it is flush with the base plate. The hex hole is still 1/8th inch deep so I will be able to replace later on if necessary.




On to post number 2.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Mon Jan 18, 2016 4:09 pm

This picture shows the front of the tensioner.


This picture shows the finished tensioners.


I was pleasantly surprised how easy this modification is to do with minimum tools. Items:

hacksaw
Punch/chisel - to remove old stud after hacksaw used to remove old idler
17 mm socket
6 mm hex drive
10 mm by 25 mm flat countersunk bolt
nylock nut with flat washer
Gates 42105 idler

Total cost for this mod is approximately $90.00. I did not need to use a 1/2 inch drill bit that I bought specifically for this, so the resulting would have been $84.00, significantly less than 2 new timing belt tensioners from mother Honda.

Cheers

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

Ernest

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roadwanderer2
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Re: 1985 GL1200 LE Maintenance

Post by roadwanderer2 » Mon Jan 18, 2016 5:21 pm

you got that right. OEM belt pulleys run around $75 bucks US each. nice job putting them together. they came out nicely done.

stuart.

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Mon Jan 18, 2016 9:48 pm

Stuart - thanks for the comments. My local Honda dealer quoted me $100.00 CDN, plus tax of course. Installed them this afternoon, set the crank sensor at 0.7mm. Almost had a heart attack when I went to put on the covers, didn't fit. A few expletives later I realized that the covers won't go on the wrong side, after which everything went well. Have to stop cleaning up after myself and moving things around. Sure is nice to have more parts going on then coming off. Cheers

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

Ernest

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Mon Jan 18, 2016 10:16 pm

I forgot to mention that during the timing belt change, I left the plugs in so that I was certain the engine would not move. I took the plugs out today so that I could move the engine just a bit to line up the crank sensor so I could set the air gap. I will be turning it tomorrow with the bolt at the aft end of the engine. I understand that it must be turned in the clockwise direction only. Cheers

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

Ernest

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roadwanderer2
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Location: sweetwater, Tennessee
Motorcycle: previously owned 83 GL1100A aspencade traded for a motorhome, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. now own-1986 GL1200 aspencade SEi
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Re: 1985 GL1200 LE Maintenance

Post by roadwanderer2 » Tue Jan 19, 2016 8:41 am

Rednaxs60 wrote:I forgot to mention that during the timing belt change, I left the plugs in so that I was certain the engine would not move. I took the plugs out today so that I could move the engine just a bit to line up the crank sensor so I could set the air gap. I will be turning it tomorrow with the bolt at the aft end of the engine. I understand that it must be turned in the clockwise direction only. Cheers

Ernest
yes, you can turn the engine by hand with the bolt located in the back of the motor. not sure if the air gap is the same, but the 86 pulse air gap is at .04. if you can lock the motor where it is using 2 "C" clamps, (one on each crank pulley), that will be your best bet. the engine shouldn't move and you can replace your belts without any problems. you can be a half tooth off and it should still be ok. if you still have any doubts, you can read thru this...........viewtopic.php?f=14&t=9774&p=175135&hili ... ts#p175135

start at the top of the page and work your way down. pay close attention to where you see the arrows and "up" on the crank pulleys. this is where your pulleys will be once everything is lined up and is basically the same for most of the 1000, 1100, 1200's and possibly the 1500's.

stuart.

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Tue Jan 19, 2016 6:19 pm

Taking a break to have a coffee adn do a quick update. Have the timing covers back on. Rotated the engine this morning and all is well. Also put the "taps" in so I can check the TPS. Have a few pictures of my progress.

First, location and start of job:




This one shows the TPS with sensor wires exposed:


I cut the wires and spliced (soldered) in new wires and pulled these through by taping them to the wires attached to the connector:




Now for post number 2.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Tue Jan 19, 2016 6:24 pm

The wiring went really well. No issues.

This picture shows the splice of the wires from the connector and TPS connected to the "tap"wires:


The next few show the routing and final spot for the wires:




One more post to go.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: 1985 GL1200 LE Maintenance

Post by Rednaxs60 » Tue Jan 19, 2016 6:29 pm

I made the protective covers that are on the "tap" wires. This is what I did.

This is a picture of the plastic protective covers I wanted to duplicate:


First I crimped and put shrink tubing (3/16") on the end of the connector:


I then cut 1/4 inch shrink tubing and placed over the connector:


The final look:


This picture shows how the inside of the cover looks:


Good bit of work so far;

Cheers

Ernest


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

Ernest

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