1985 GL1200 LE Maintenance - Post Maintenance Report


Information and questions on GL1200 Goldwings (1984-1987)
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Rednaxs60
Posts: 720
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD, 2008 GL1800

1985 GL1200 LE Maintenance - Post Maintenance Report

Postby Rednaxs60 » Sat Jan 23, 2016 2:44 pm



To finish this maintenance period, I want to summarize what I have done, provide P/Ns, and identify some issues that I was confronted with that are not necessarily found in the manuals, but are available through the collective information that can be found on this and other forums with a lot of looking.

Issues:

Removal and replacement of the starter requires the exhaust system to be dropped and the exhaust stud in front of the starter removed.

To remove the engine guards requires the exhaust system to be dropped. Installation of the engine guards has to be done before the exhaust system is put put in place.

Installation of the shifter seal is better done when exhaust is down and left engine guard is removed.

The crank pulse sensor can be installed below or above the crank shaft pulse sensor wheel as there is no timing implcations.

The work/maintenance completed:

Suspension upgrade front and rear
Rebuild of front and rear brake callipers
New brake pads front and rear
Front and rear brakes, and clutch hydraulic systems fluid flush and bleed
New brake rotors front and rear
Clean up of wiring add-ons for heated handgrips, driving lights, 12VDC adapter
New battery
New ground bus bar
New accessory fuse block
New shifter oil seal
New exhaust studs and nuts
New exhaust gaskets
Rebuild timing belt tensioners
New timing belts
New valve cover gaskets
Flush coolant system, add new coolant
Replace spark plugs
Replace air filter
Coil Mod: addition of relay to improve 12VDC supply to coils
Reg/Reg Sensing Wire Mod: addition of relay to improve 12VDC signal
Accessory fuse block switching relay – to turn power off to fuse block when ignition off
Soldering of stator – reg/rec wires, and reg/rec and electrical system wiring
Installation of wire taps in TPS wire harness to test TPS
Used marine grade shrink tubing with a 3:1 shrinkage rate
Miscellaneous wire: black for sensing wires - red for 12VDC - green for ground
Miscellaneous solderless connectors

Parts and P/Ns used for maintenance:

Brake calliper rebuild – The front callipers use different size parts. The left calliper uses the same parts as the rear calliper. The right front calliper is linked to the rear brake, and has smaller pistons and seals then the left front calliper.

Front left calliper:

Sleeve - 45111-MA3-006 (qty 1)
Dust Seal - 45109-MA7-006 (qty 2)
Piston Seal - 45209-MA7-006 (qty 2)
Boot-Pin - 45133-166-016 (qty 3)

Rear calliper:

Sleeve - 45111-MA3-006 (qty 1)
Dust Seal - 45109-MA7-006 (qty 2)
Piston Seal - 45209-MA7-006 (qty 2)
Boot-Pin - 45133-166-016 (qty 3)

Front right calliper: piston size is 25.4mm

Boot-Pin - 45133-166-016 (qty 3)
Sleeve - 45111-MA3-006 (qty 1)
Dust Seal – 45109-GE2-006 (qty 2)
Piston Seal - 45209-GE2-006 (qty 2)

Front Rotors – EBC MD1125
Rear Brake Pads - KapscoMoto PAD69-V46 (qty 1 set)
Front Brake Pads - KapscoMoto PAD69-V33 (qty 2 sets) Note: different P/Ns but pads are the same front and back

boot holders - rear piston case on front forks - 51445-MC7-003 (qty 4)

Shifter Oil Seal – 91206-286-013

Valve Cover Gaskets – 12328-MG9-000 (qty 2)
Valve Cover Securing Bolt Rubber Mounts – 90542-MB0-000 (qty 4)

Exhaust Gaskets – 18291-286-306 (qty 4)
Exhaust Studs – 90035-371-000 (qty 8)
Exhaust Nuts – 94070-08080 (qty 8 – combination nut and washer)

Timing Belt Tensioner Idler Pulley – Gates 42015 (qty 2)

This has been a fun and interesting learning experience. Thanks to all for their input. The information in this and other forums is invaluable to maintaining and keeping an older GW operating. Cheers

Ernest


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

Ernest

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Rednaxs60
Posts: 720
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD, 2008 GL1800

Re: 1985 GL1200 LE Maintenance - Post Maintenance Report

Postby Rednaxs60 » Sun Jan 24, 2016 10:58 am

Addendum to first post - replaced starter solenoid. Did this beause the new starter relay comes with the new blade fuse integral to the relay and has a spare as well. The original was starting to show wear and possible overheating, and lastly, real estate in the area next to the battery is at a premium and you can ony stuff so much into this space. I was also reminded of this because I read a thread regarding the dog bone fuse(s) on the 1200. Also replaced the in-line 30 amp dog bone fuse from the starter relay to the ignition switch with a blade type 30 amp fuse. Cheers

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

Ernest

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Rednaxs60
Posts: 720
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD, 2008 GL1800

Re: 1985 GL1200 LE Maintenance - Post Maintenance Report

Postby Rednaxs60 » Mon Jan 25, 2016 9:06 pm

More info for future maintenance - Crankshaft Angle Sensor

This sensor can be installed in the upper or lower position - only measures crankshaft angle. In order to remove the timing belts, this sensor has to be removed. The air gap is between 0.4 mm and 0.9 mm.
"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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Motorcycle: 83 GL1100A aspencade, previously owned, 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. and a new to me 1986 GL1200 aspencade SEi
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Re: 1985 GL1200 LE Maintenance - Post Maintenance Report

Postby roadwanderer2 » Mon Jan 25, 2016 9:26 pm

rednaxs, you did one heck of a job on your bike. your photos, descriptions of what and how you did it are great. now, when the weather gets better, when are you coming to do mine? lol.

stuart.

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julimike54
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Location: Euless, Texas
Motorcycle: 1986 GL1200A original owner
2016 HD FLTRU

Re: 1985 GL1200 LE Maintenance - Post Maintenance Report

Postby julimike54 » Thu Jan 28, 2016 9:15 am

Did you check out the water pump, I may have missed that? Mine I found the drain hole packed tightly with muck, didn't appear to leak. Cleaned it out & had oil leak, had to rework the water pump.
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Riding anything is a good day!
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Rednaxs60
Posts: 720
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD, 2008 GL1800

Re: 1985 GL1200 LE Maintenance - Post Maintenance Report

Postby Rednaxs60 » Thu Jan 28, 2016 9:29 am

julimike54 wrote:Did you check out the water pump, I may have missed that? Mine I found the drain hole packed tightly with muck, didn't appear to leak. Cleaned it out & had oil leak, had to rework the water pump.


Missed this one. Will check. Thanks
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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julimike54
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Joined: Sun Feb 01, 2015 12:21 pm
Location: Euless, Texas
Motorcycle: 1986 GL1200A original owner
2016 HD FLTRU

Re: 1985 GL1200 LE Maintenance - Post Maintenance Report

Postby julimike54 » Thu Jan 28, 2016 12:19 pm

There are a couple of checks. One, anything leaking from weep hole; two, when flushing coolant & empty reach in to water pump with fingers & try to wiggle pump shaft around. It should not move much at all, if the bearings are ok. My understanding is that bearings or seals can fail, but both don't have to fail together :?
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Riding anything is a good day!
Mike

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Rednaxs60
Posts: 720
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD, 2008 GL1800

Re: 1985 GL1200 LE Maintenance - Post Maintenance Report

Postby Rednaxs60 » Mon Feb 15, 2016 12:35 pm

Wanted to replace the brake lines with SS braided Teflon lines. Coast Industrial here in Victoria makes these lines using the old lines as templates. Cost for the rear brake line was $52.00 that is comparable to getting lines from the US and there is no shipping charges, or possible duty implications. Coast Industrial can be contacted at 250-475-3202.

Also changed the short hose from the rear brake fluid reservoir to the rear brake MC. Had read that some on this forum had found that some of the hoses on brake systems had deteriorated such that the inside was "flaking" off and clogging the MC.


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

Ernest


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